Method for generating numerical control program, element creation method, generation system, and generation program

ABSTRACT

A method for generating a numerical control program includes first-fourth steps. In the first step, elements related to the shape of a material are created on the basis of information related to the shape of the material. In the second step, processing is executed in which the elements related to the shape of the material which were created in the first step are read into areas to be subjected to processing in the third step. In the third step, a tool path is generated for each element read in the second step. In the fourth step, the tool paths generated for each element in the third step are connected.

RELATED APPLICATIONS

The present application is a National Phase of International ApplicationNumber PCT/JP2017/024850 filed Jul. 6, 2017 and claims priority fromJapanese Application Number 2016-162997 filed Aug. 23, 2016.

TECHNICAL FIELD

The present invention relates to a method for generating a numericalcontrol program, an element creation method, a numerical control programgeneration system, and a numerical control program generation program.

BACKGROUND ART

In order to control a processing operation in machining performed duringprocessing of a material, a numerical control program (NC program) isused. A single numerical control program is created through programmingfor each material. A numerical control program for a material related tomany similar components is created by using a model program created fora general material (refer to PTL 1).

CITATION LIST Patent Literature

-   [PTL 1] Japanese Unexamined Patent Application Publication No.    2008-140358

SUMMARY OF INVENTION Technical Problem

In a method disclosed in PTL 1, a processing shape recognition techniqueaccording to changes in processing shapes is used in a process ofextracting a processing shape from three-dimensional data of a material.However, in the method disclosed in PTL 1, a processing shape can beextracted, but a cutting condition corresponding to a processing shapecannot be set, and the cutting condition is required to be separatelyset. Thus, in the method disclosed in PTL 1, it is difficult to generatea tool path in which a route of a processing operation is codedaccording to a processing shape.

The present invention has been made in light of the above description,and an object thereof is to provide a method for generating a numericalcontrol program, an element creation method, a numerical control programgeneration system, and a numerical control program generation program,capable of setting a cutting condition corresponding to a processingshape and generating a tool path in which a route of a processingoperation is coded according to the processing shape.

Solution to Problem

In order to solve the problem, and to achieve the object, there isprovided a method for generating a numerical control program forcontrolling a processing operation in machining performed duringprocessing of a material, the method including an element creation step,executed by a computer aided design program, of creating elementsregarding a shape of the material on the basis of a material designmodel which is a design model for the material; an element reading stepof reading the elements created by the computer aided design program ina computer aided manufacturing program; a tool path generation step ofgenerating a tool path in which a route of the processing operation iscoded, for each of the read elements, by executing the computer aidedmanufacturing program; and a tool path connection step of connecting thegenerated tool paths to each other so as to create a numerical controlprogram by executing the computer aided manufacturing program.

According to this configuration, since elements regarding a shape of thematerial created in the element creation step are used for the tool pathgeneration step of generating a tool path in which a route of theprocessing operation is coded through the element reading step, acutting condition corresponding to a processing shape can be set, andthus it is possible to generate a tool path in which a route of theprocessing operation is coded according to the processing shape.

In this configuration, preferably, in the element creation step, amongexisting material design models prepared in advance, a similar materialdesign model having a shape closest to the material design model iscompared with the material design model, and the elements are created bycorrelating corresponding portions between the material design model andthe similar material design model with each other; in the elementreading step, a similarity and a difference are read with respect to theportions correlated with each other in the element creation step; and,in the tool path generation step, a tool path generated on the basis ofthe similar material design model is used as a tool path correspondingto the element including the similarity, and a tool path to which a toolpath generated on the basis of the similar material design model ischanged according to the difference is generated as a tool pathcorresponding to the element including the difference. According to thisconfiguration, it is possible to highly accurately create a numericalcontrol program regarding processing of a material having a large numberof considerably similar shapes.

In the configuration using the similar design model, in the elementcreation step, the similar material design model is preferably selectedon the basis of at least one of a raw material used for the material,the type and a size of a shape of the material design model, an angle ofa flange provided in the material design model, the extent of change ina plate thickness of the flange, and the presence or absence of a mousehole. According to this configuration, it is possible to select asimilar material design model with high accuracy.

In this configuration, preferably, in the element creation step, surfaceelements included in the material are extracted, a surface elementincluding a straight line corresponding to the longest distance betweentwo points is set as a first reference surface among the surfaceelements, a surface element including a straight line corresponding tothe longest distance between two points is set as a second referencesurface among surface elements in a direction orthogonal to the firstreference surface, coordinate axes having an intersection line betweenthe first reference surface and the second reference surface as an Xaxis and any one straight line orthogonal to the first reference surfaceas a Z axis are created, and elements of the material are created byusing the created coordinate axes as references. According to thisconfiguration, it is possible to automatically create an element withhigh accuracy.

In this configuration, preferably, in the element creation step, surfaceelements, end part elements, an cross part element where two or moresurface elements cross each other are set, and some of the surfaceelements and the cross part elements influenced by the rigidity of thematerial are set as elements for generating the tool path by usingcutting condition setting elements which are elements for settingconditions for a processing operation. According to this configuration,it is possible to efficiently set a cutting condition for only anelement for which the cutting condition is required to be set, accordingto a processing shape.

In the configuration of setting surface elements, an end part element,and a cross part element, preferably, in the element reading step,information regarding whether or not an element is set in the cuttingcondition setting elements is read, and, in the tool path generationstep, a cutting condition is created on the basis of the cuttingcondition setting elements with respect to an element which is set as anelement for generating the tool path by using the cutting conditionsetting elements, and a tool path satisfying the cutting condition iscreated. According to this configuration, it is possible to efficientlyset a cutting condition for only an element for which the cuttingcondition is required to be set, according to a processing shape.

In the configuration of creating a cutting condition on the basis ofcutting condition setting elements, preferably, in the tool pathgeneration step, the cutting condition is generated on the basis of apower ratio which is a ratio between cutting power of a tool used forthe machining and an approximate value of static rigidity of theelement, and a tilt amount which is a ratio between cutting force of thetool and the approximate value of the static rigidity. According to thisconfiguration, it is possible to highly accurately set a cuttingcondition for only an element for which the cutting condition isrequired to be set, according to a processing shape.

In this configuration, preferably, in the tool path connection step, thetool paths are connected to each other in an order of the tool pathcorresponding to the element close to a grip portion which is grippedduring processing of the material from the tool path corresponding tothe element far from the grip portion. According to this configuration,it is possible to generate a numerical control program causing a highyield of processing of a material.

In this configuration, preferably, the method for generating a numericalcontrol program further includes a numerical control programverification step, and, in the numerical control program verificationstep, it is verified whether or not the material, a grip member grippingthe material, and a tool processing the material physically interferewith each other in a case where the created numerical control program isexecuted after the tool path connection step. According to thisconfiguration, it is possible to verify whether or not the numericalcontrol program will be appropriately used before being used forprocessing of the material.

In order to solve the problem, and to achieve the object, there isprovided an element creation method of creating elements of a designmodel for a material, the method including extracting all planeelements; setting a plane element including a straight linecorresponding to the longest distance between two points as a firstreference surface among the plane elements; setting a plane elementincluding a straight line corresponding to the longest distance betweentwo points as a second reference surface among plane elements orthogonalto the first reference surface; creating coordinate axes having anintersection line between the first reference surface and the secondreference surface as an X axis and any one straight line orthogonal tothe first reference surface as a Z axis; and creating elements of thematerial by using the created coordinate axes as references. Accordingto this configuration, it is possible to automatically create an elementof the material with high accuracy.

In order to solve the problem, and to achieve the object, there isprovided a system generating a numerical control program for controllinga processing operation in machining performed during processing of amaterial, the system including a control section, in which the controlsection executes respective steps including an element creation step,executed by a computer aided design program, of creating elementsregarding a shape of the material on the basis of a design model for thematerial; an element reading step of reading the elements created by thecomputer aided design program in a computer aided manufacturing program;a tool path generation step of generating a tool path in which a routeof the processing operation is coded, for each of the read elements, byexecuting the computer aided manufacturing program; and a tool pathconnection step of connecting the generated tool paths to each other soas to create a numerical control program by executing the computer aidedmanufacturing program. According to this configuration, since elementsregarding a shape of the material created in the element creation stepare used for the tool path generation step of generating a tool path inwhich a route of the processing operation is coded through the elementreading step, a cutting condition corresponding to a processing shapecan be set, and thus it is possible to generate a tool path in which aroute of the processing operation is coded according to the processingshape.

In order to solve the problem, and to achieve the object, there isprovided a numerical control program generation program causing acomputer to generate a numerical control program for controlling aprocessing operation in machining performed during processing of amaterial, the program causing the computer to execute an elementcreation step, executed by a computer aided design program, of creatingelements regarding a shape of the material on the basis of a materialdesign model which is a design model for the material; an elementreading step of reading the elements created by the computer aideddesign program in a computer aided manufacturing program; a tool pathgeneration step of generating a tool path in which a route of theprocessing operation is coded, for each of the read elements, byexecuting the computer aided manufacturing program; and a tool pathconnection step of connecting the created tool paths to each other so asto create a numerical control program by executing the computer aidedmanufacturing program. According to this configuration, since elementsregarding a shape of the material created in the element creation stepare used for the tool path generation step of generating a tool path inwhich a route of the processing operation is coded through the elementreading step, a cutting condition corresponding to a processing shapecan be set, and thus it is possible to generate a tool path in which aroute of the processing operation is coded according to the processingshape.

Advantageous Effects of Invention

According to the present invention, it is possible to provide a methodfor generating a numerical control program, an element creation method,a numerical control program generation system, and a numerical controlprogram generation program, capable of setting a cutting conditioncorresponding to a processing shape and generating a tool path in whicha route of a processing operation is coded according to the processingshape.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a schematic configuration diagram illustrating an example of amaterial processing system according to an embodiment of the presentinvention.

FIG. 2 is a side view illustrating an example of a material obtainedthrough processing in the material processing system.

FIG. 3 is a side view illustrating an example of a material obtainedthrough processing in the material processing system.

FIG. 4 is a side view illustrating an example of a material obtainedthrough processing in the material processing system.

FIG. 5 is a side view illustrating an example of a material obtainedthrough processing in the material processing system.

FIG. 6 is a side view illustrating an example of a material obtainedthrough processing in the material processing system.

FIG. 7 is a side view illustrating an example of a material obtainedthrough processing in the material processing system.

FIG. 8 is a side view illustrating an example of a material obtainedthrough processing in the material processing system.

FIG. 9 is a side view illustrating an example of a material obtainedthrough processing in the material processing system.

FIG. 10 is a side view illustrating an example of a material obtainedthrough processing in the material processing system.

FIG. 11 is a sectional view illustrating an example of a curved portion.

FIG. 12 is a sectional view illustrating an example of a taperedportion.

FIG. 13 is a sectional view illustrating an example of a step portion.

FIG. 14 is a sectional view illustrating an example of a step portion.

FIG. 15 is a flowchart illustrating an example of a flow of a rawmaterial shape determination method.

FIG. 16 is a flowchart illustrating an example of a detailed flow of aflange classification step.

FIG. 17 is a flowchart illustrating an example of a detailed flow of agrip portion setting step.

FIG. 18 is a flowchart illustrating an example of a detailed flow of araw material shape calculation step.

FIG. 19 is a side view illustrating an example of a raw materialdetermined in the raw material shape determination method.

FIG. 20 is a side view illustrating an example of a raw materialdetermined in the raw material shape determination method.

FIG. 21 is a side view illustrating an example of a raw materialdetermined in the raw material shape determination method.

FIG. 22 is a side view illustrating an example of a raw materialdetermined in the raw material shape determination method.

FIG. 23 is a side view illustrating an example of a raw materialdetermined in the raw material shape determination method.

FIG. 24 is a side view illustrating an example of a raw materialdetermined in the raw material shape determination method.

FIG. 25 is a side view illustrating an example of a raw materialdetermined in the raw material shape determination method.

FIG. 26 is a side view illustrating an example of a raw materialdetermined in the raw material shape determination method.

FIG. 27 is a side view illustrating an example of a raw materialdetermined in the raw material shape determination method.

FIG. 28 is a flowchart illustrating an example of a flow of a numericalcontrol program generation method.

FIG. 29 is a flowchart illustrating an example of a detailed flow of anelement creation step.

FIG. 30 is a perspective view illustrating a material design model whichis an example of a material shape.

FIG. 31 is a diagram illustrating examples of identification conditionsfor the material design model.

FIG. 32 is a sectional view illustrating an example of a flange angle of90 degrees.

FIG. 33 is a sectional view illustrating an example of a flange angle ofan acute angle.

FIG. 34 is a perspective view illustrating an example of a step portionof a flange.

FIG. 35 is a perspective view illustrating an example of a mouse hole.

FIG. 36 is a perspective view illustrating a similar material designmodel which is an example of an existing material design model and ofwhich a shape is closest to a material shape.

FIG. 37 is a flowchart illustrating an example of a detailed flow of amaterial element identification step.

FIG. 38 is a flowchart illustrating an example of a detailed flow in acase where an element of the material design model is automaticallyidentified.

FIG. 39 is a diagram illustrating an example of an automaticidentification state in a case where automatic identification isperformed on the basis of a model element name.

FIG. 40 is a diagram illustrating an example of a reference elementselection state in a case where semi-automatic identification isperformed on the basis of reference element selection.

FIG. 41 is a diagram illustrating an example of a raw material designmodel.

FIG. 42 is a diagram illustrating an example of an element divisionmethod in the raw material design model.

FIG. 43 is a diagram illustrating examples of cutting condition settingelements.

FIG. 44 is a diagram illustrating examples of tool path generationelements.

FIG. 45 is a flowchart illustrating an example of a detailed flow of atool path generation step.

FIG. 46 is a diagram illustrating an example of a stable region of atool.

FIG. 47 is a diagram illustrating roughing tool conditions which areexamples of a combination of a spindle rotation speed of a tool and afeed amount per tooth in roughing.

FIG. 48 is a diagram illustrating finishing tool conditions which areexamples of a combination of a spindle rotation speed of a tool and afeed amount per tooth in finishing.

FIG. 49 is a diagram illustrating an example of an order of processingof a main plate raw material portion.

FIG. 50 is a diagram illustrating an example of an order of processingof a flange raw material portion.

FIG. 51 is a diagram illustrating an example of a relationship between afeed amount per tooth and a specific cutting resistance.

FIG. 52 is a diagram illustrating an example of cutting conditioncalculation.

FIG. 53 is a flowchart illustrating an example of a flow of a processingmethod.

FIG. 54 is a side view illustrating an example of a gripping step.

FIG. 55 is a side view illustrating an example of a gripping step.

FIG. 56 is a side view illustrating an example of a gripping step.

FIG. 57 is a side view illustrating an example of a gripping step.

FIG. 58 is a side view illustrating an example of a gripping step.

FIG. 59 is a flowchart illustrating a detailed example of a flow of acutting step.

FIG. 60 is a flowchart illustrating another detailed example of a flowof a cutting step.

FIG. 61 is a flowchart illustrating a detailed example of a flow of aprocessing method including a boring step.

FIG. 62 is a diagram illustrating an example of an order of processingof a main plate raw material portion including a boring part.

FIG. 63 is a diagram illustrating an example of an order of processingof a flange raw material portion including a boring part.

FIG. 64 is a flowchart illustrating a detailed example of a flow of aprocessing method including a depression forming step.

FIG. 65 is a diagram illustrating an example of an order of processingof a portion including a depression forming part.

DESCRIPTION OF EMBODIMENTS

Hereinafter, an embodiment according to the present invention will bedescribed with reference to the drawings. The invention is not limitedto the embodiment. A constituent element in the embodiment includesconstituent elements which are replaceable and are easily replaced, or asubstantially identical constituent element. Constituent elementsdescribed below may be combined with each other as appropriate.

Embodiment

FIG. 1 is a schematic configuration diagram illustrating a materialprocessing system 10 which is an example of a material processing systemaccording to an embodiment of the present invention. As illustrated inFIG. 1, the material processing system 10 includes a raw material shapedetermination system 11, a numerical control program generation system12, and a machining device 13.

The raw material shape determination system 11 includes a controlsection 11 c. The control section 11 c includes a storage unit and aprocessing unit. The storage unit includes, for example, storage devicessuch as a RAM, a ROM, and a flash memory, and stores a software programprocessed by the processing unit, data referred to by the softwareprogram, and the like. Specifically, the storage unit stores a rawmaterial shape determination program 15 causing the processing unit toexecute a raw material shape determination method. The storage unit alsofunctions as a storage region in which the processing unit temporarilystores a processing result. The processing unit reads the softwareprogram or the like from the storage unit, and processes the softwareprogram, so as to realize a function corresponding to the softwareprogram. Specifically, the processing unit reads and processes the rawmaterial shape determination program 15 stored in the storage unit, soas to execute a raw material shape determination method. An example ofthe raw material shape determination system 11 is a computer.

The raw material shape determination program 15 is, for example, acomputer aided design (CAD) and a macro-function incorporated into theCAD. The macro-function incorporated into the CAD is, for example, amacro-function of Computer graphics Aided Three dimensional InteractiveApplication (CATIA) (registered trademark).

The numerical control program generation system 12 includes a controlsection 12 c. The control section 12 c includes a storage unit and aprocessing unit. The storage unit includes, for example, storage devicessuch as a RAM, a ROM, and a flash memory, and stores a software programprocessed by the processing unit, data referred to by the softwareprogram, and the like. Specifically, the storage unit stores a numericalcontrol program generation program causing the processing unit toexecute a numerical control program generation method. The storage unitalso functions as a storage region in which the processing unittemporarily stores a processing result. The processing unit reads thesoftware program or the like from the storage unit, and processes thesoftware program, so as to realize a function corresponding to thesoftware program. Specifically, the processing unit reads and processesthe numerical control program generation program 16 stored in thestorage unit, so as to execute a numerical control program generationmethod and thus to generate numerical control program (NC program) 19.The numerical control program generation system 12 is, for example, acomputer.

The numerical control program generation program 16 includes a computeraided design program 17 and a computer aided manufacturing program 18.The computer aided design program 17 is, for example, a computer aideddesign (CAD) and a macro-function incorporated into the CAD. Themacro-function incorporated into the CAD is, for example, amacro-function of Computer graphics Aided Three dimensional InteractiveApplication (CATIA) (registered trademark). The computer aidedmanufacturing program 18 is, for example, computer aided manufacturing(CAM). The numerical control program 19 is a program for controlling aprocessing operation in machining performed on a material.

The control section 12 c is not limited to an integrated one, and mayinclude, for example, a first control unit storing and processing thecomputer aided design program 17 and a second control unit storing andprocessing the computer aided manufacturing program 18. In other words,the numerical control program generation program 16 may be divided to bestored and executed by a plurality of control units.

The machining device 13 includes a control section 13 c. The controlsection 13 c includes a storage unit and a processing unit. The storageunit includes, for example, storage devices such as a RAM, a ROM, and aflash memory, and stores a software program processed by the processingunit, data referred to by the software program, and the like.Specifically, the storage unit stores the numerical control program 19causing the processing unit to execute a processing method which is aprocessing operation in machining performed on a material. The storageunit also functions as a storage region in which the processing unittemporarily stores a processing result. The processing unit reads thesoftware program or the like from the storage unit, and processes thesoftware program, so as to realize a function corresponding to thesoftware program. Specifically, the processing unit reads and processesthe numerical control program 19 stored in the storage unit, so as toexecute a processing method and thus to process a material. Themachining device 13 is, for example, machine tools.

Examples of materials obtained through processing in the materialprocessing system 10 will be described below. FIG. 2 is a side viewillustrating a material 20 which is an example of a material 20 obtainedthrough processing in the material processing system 10. The material 20has a main plate portion 20 w as illustrated in FIG. 2. The main plateportion 20 w has a tabular shape, and is a portion which is formed toextend along an axial direction A and includes a surface elementincluding a straight line corresponding to the longest distance betweentwo points. The main plate portion 20 w is also referred to as a web dueto a widely extending shape.

In the main plate portion 20 w, a height in a plane along the maximumsurface element, that is, a height in a direction orthogonal to theaxial direction A is h_(w). In the main plate portion 20 w, a length inthe plane along the maximum surface element, that is, a length along theaxial direction A is l_(w). In the main plate portion 20 w, a platethickness in a direction orthogonal to the maximum surface element ist_(w).

The entire height of the material 20, that is, the entire size of thematerial 20 along the direction of the height of the main plate portion20 w is h. In a case of the material 20, the entire height h of thematerial 20 is the same as the height h_(w) of the main plate portion 20w. The entire length of the material 20, that is, the entire size of thematerial 20 along the direction of the length of the main plate portion20 w is 1. In a case of the material 20, the entire length l of thematerial 20 is the same as the length l_(w) of the main plate portion 20w. The entire width of the material 20, that is, the entire size of thematerial 20 along the direction of the plate thickness of the main plateportion 20 w is w. In a case of the material 20, the entire width w ofthe material 20 is the same as the plate thickness t_(w) of the mainplate portion 20 w.

The material 20 does not have a flange. The material 20 is referred toas an I type since a shape of the side surface viewed from the directionorthogonal to the axial direction A is similar to the alphabet characterI. The I type material exemplified by the material 20 has a shape usedas a reference of a material obtained through processing in the materialprocessing system 10.

In addition to the material 20 illustrated in FIG. 2, in each of allmaterials described below, a surface element including a straight linecorresponding to the longest distance between two points in the materialwill be referred to as the maximum surface element. Similarly, a portionwhich has a tabular shape, is formed to extend in the axial direction,and includes the maximum surface element in the materials will bereferred to as a main plate portion. Similarly, in the main plateportion, a height in a plane along the maximum surface element, that is,a height in a direction orthogonal to the axial direction will bereferred to as a height of the main plate portion. Similarly, in themain plate portion, a length in the plane along the maximum surfaceelement, that is, a length in a direction along the axial direction willbe referred to as a length of the main plate portion. Similarly, in themain plate portion, a plate thickness in a direction orthogonal to themaximum surface element will be referred to as a plate thickness of themain plate portion. Similarly, the entire size of a material along thedirection of the height of the main plate portion will be referred to asthe entire height of the material. Similarly, the entire size of amaterial along the direction of the length of the main plate portionwill be referred to as the entire length of the material. Similarly, theentire size of a material along the direction of the plate thickness ofthe main plate portion will be referred to as the entire width of thematerial. Similarly, the main plate portion will be also referred to asa web due to a widely extending shape.

FIG. 3 is a side view illustrating a material 22 which is an example ofa material obtained through processing in the material processing system10. As illustrated in FIG. 3, the material 22 has a main plate portion22 w, a flange 22 f, and a cross part 22 m. An axial direction in thematerial 22 is parallel to a direction orthogonal to the drawing surfaceof FIG. 3. The flange 22 f is a portion which is formed to extend in theaxial direction, and is provided to extend in a direction intersectingthe maximum surface element from the main plate portion 22 w. The crosspart 22 m is a portion where the main plate portion 22 w and the flange22 f intersect each other, and includes a circular arc portion in a sideview orthogonal to the axial direction.

A height of the main plate portion 22 w in the material 22, a length ofthe main plate portion 22 w, and a plate thickness of the main plateportion 22 w are given the same reference signs as those of the material20, and are respectively h_(w), l_(w), and t_(w). The length l_(w) ofthe main plate portion 22 w is not illustrated in FIG. 3.

In the flange 22 f, a distance extending along a surface direction ofthe flange 22 f and a direction orthogonal to the axial direction, thatis, a height of the flange 22 f which is a distance from the main plateportion 22 w to a distal end of the flange 22 f is h_(f). In the flange22 f, a length of the flange 22 f which is a distance extending alongthe surface direction of the flange 22 f and along the axial directionis l_(f). The length l_(f) corresponds to and is substantially the sameas the length l of the main plate portion 22 w, and thus not illustratedin FIG. 3. In the flange 22 f, a plate thickness of the flange 22 fwhich is a distance along a direction orthogonal to the surfacedirection of the flange 22 f is t_(f).

The flange 22 f is provided at a predetermined inter-surface angle withthe main plate portion 22 w. The predetermined inter-surface angleformed between the flange 22 f and the main plate portion 22 w will bereferred to as a flange angle of the flange 22 f. The flange 22 f isprovided to be orthogonal to the main plate portion 22 w. In otherwords, a flange angle of the flange 22 f is 90 degrees. The flange 22 fis provided on one surface side of the main plate portion 22 w,specifically, on the right side in the drawing surface of FIG. 3.

The flange 22 f is provided at one end part of the main plate portion 22w, specifically, at the upper end part in the drawing surface of FIG. 3.In other words, a flange position which is a position of the flange 22 fin the main plate portion 22 w is an end part. A flange position in thematerial 22 is, specifically, a central position in the direction of theplate thickness t_(f) of the flange 22 f in the main plate portion 22 w,and is calculated as a value obtained by subtracting a half of the platethickness t_(f) of the flange 22 f from the height h_(w) of the mainplate portion 22 w with the end part of the main plate portion 22 w nothaving the flange 22 f, that is, the end part on the lower side in thedrawing surface of FIG. 3 as the origin, in a case where the flange 22 fis provided at the end part, and a flange angle is 90 degrees.

The material 22 has the above-described configuration, and thus theentire height h of the material 22 is the same as the height h_(w) ofthe main plate portion 22 w. The entire length l of the material 22 isthe same as a larger length of the length l_(w) of the main plateportion 22 w and the length l_(f) of the flange 22 f. The entire width wof the material 22 is the same as a sum of the half of the platethickness t of the main plate portion 22 w and the height h_(f) of theflange 22 f.

The material 22 has the flange 22 f of which a flange angle is 90degrees on one surface side of one end part of the main plate portion 22w. Thus, the material 22 will be referred to as an L type since a shapeof the side surface viewed from the direction orthogonal to the axialdirection is similar to the alphabet character L. The flange 22 f willbe referred to as an L type flange.

In addition to the material 22 illustrated in FIG. 3, in each of allmaterials described below, a portion which is formed to extend in theaxial direction, and is provided to extend in a direction intersectingthe maximum surface element from the main plate portion will be referredto as a flange. Similarly, a portion where the main plate portion andthe flange intersect each other, and includes a circular arc portion ina side view orthogonal to the axial direction will be referred to as across part. Similarly, in the flange, a distance extending along asurface direction of the flange 22 f and a direction orthogonal to theaxial direction, that is, a distance from the main plate portion to adistal end of the flange 22 f will be referred to as a height of theflange. Similarly, in the flange, a distance extending along the surfacedirection of the flange and along the axial direction will be referredto as a length of the flange. Similarly, in the flange, a distance alonga direction orthogonal to the surface direction of the flange will bereferred to as a plate thickness of the flange. Similarly, apredetermined inter-surface angle formed between the flange and the mainplate portion will be referred to as a flange angle. Similarly, acentral position in a direction of the plate thickness of the flange inthe main plate portion will be referred to as a flange position.

FIG. 4 is a side view illustrating a material 24 which is an example ofa material obtained through processing in the material processing system10. As illustrated in FIG. 4, the material 24 has a main plate portion24 w, a flange 24 f, and a cross part 24 m. An axial direction in thematerial 24 is parallel to a direction orthogonal to the drawing surfaceof FIG. 4. A height of the main plate portion 24 w in the material 24, alength of the main plate portion 24 w, and a plate thickness of the mainplate portion 24 w are given the same reference signs as those of thematerial 20 and material 22, and are respectively h_(w), l_(w), andt_(w). A height of the flange 24 f in the material 24, a length of theflange 24 f, and a plate thickness of the flange 24 f are given the samereference signs as those of the material 22, and are respectively h_(f),l_(f), and t_(f). The length l_(w) of the main plate portion 24 w andthe length l_(f) of the flange 24 f are not illustrated in FIG. 4.

A flange angle of the flange 24 f in the material 24 is (90+θ) degrees.Here, θ is a value greater than 0 degrees and smaller than 90 degrees.The flange 24 f is provided on one surface side of the main plateportion 24 w, specifically, on the right side in the drawing surface ofFIG. 4. The flange 24 f is provided at one end part of the main plateportion 24 w, specifically, at the upper end part in the drawing surfaceof FIG. 4. In other words, a flange position of the flange 24 f iscalculated as a value obtained by subtracting a product of a half of theplate thickness t_(f) of the flange 24 f and cos θ corresponding to acosine component of the flange angle from the height h_(w) of the mainplate portion 24 w with the end part of the main plate portion 24 w nothaving the flange 24 f, that is, the end part on the lower side in thedrawing surface of FIG. 4 as the origin.

The material 24 has the above-described configuration, and thus theentire height h of the material 24 is the same as a sum of the heighth_(w) of the main plate portion 24 w, and a product of the height h_(f)of the flange 24 f and sin θ corresponding to a sine component of theflange angle. The entire length l of the material 24 is the same as alarger length of the length l_(w) of the main plate portion 24 w and thelength l_(f) of the flange 24 f. The entire width w of the material 24is the same as a sum of a half of the plate thickness t_(w) of the mainplate portion 24 w, a product h_(f) cos θ of the height h_(f) of theflange 24 f and cos θ corresponding to a cosine component of the flangeangle, and a product of a half of the plate thickness t_(f) of theflange 24 f and sin θ corresponding to a sine component of the flangeangle.

The material 24 is changed from 90 degrees to (90+θ) degrees in terms ofa flange angle with respect to the material 22, and is classified as anL type in the same manner as the material 22. The flange 24 f isclassified as an L type flange.

FIG. 5 is a side view illustrating a material 26 which is an example ofa material obtained through processing in the material processing system10. As illustrated in FIG. 5, the material 26 has a main plate portion26 w, a flange 26 f 1, a flange 26 f 2, and a cross part 26 m. An axialdirection in the material 26 is parallel to a direction orthogonal tothe drawing surface of FIG. 5. A height of the main plate portion 26 win the material 26, a length of the main plate portion 26 w, and a platethickness of the main plate portion 26 w are given the same referencesigns as those of the material 20, the material 22, and the material 24,and are respectively h_(w), l_(w), and t_(w). A height of the flange 26f 1 in the material 26, a length of the flange 26 f 1, and a platethickness of the flange 26 f 1 are respectively h_(f1), l_(f1), andt_(f1). A height of the flange 26 f 2 in the material 26, a length ofthe flange 26 f 2, and a plate thickness of the flange 26 f 2 arerespectively h_(f2), l_(f2), and t_(f2). The length l_(w) of the mainplate portion 26 w, the length l_(f1) of the flange 26 f 1, and thelength l_(f2) of the flange 26 f 2 are not illustrated in FIG. 5.

A flange angle of the flange 26 f 1 in the material 26 is 90 degrees. Aflange angle of the flange 26 f 2 in the material 26 is 90 degrees. Theflange 26 f 1 is provided on one surface side of the main plate portion26 w, specifically, on the right side in the drawing surface of FIG. 5.The flange 26 f 2 is provided on the other surface side of the mainplate portion 26 w, specifically, on the left side in the drawingsurface of FIG. 5. In other words, in a case where the flange 26 f 1 andthe flange 26 f 2 are viewed integrally in the material 26, the flange26 f 1 and the flange 26 f 2 are provided on both surface sides of themain plate portion 26 w.

Both of the flange 26 f 1 and the flange 26 f 2 are provided at one endpart of the main plate portion 26 w, specifically, at the upper end partin the drawing surface of FIG. 5. In other words, a flange position ofthe flange 26 f 1 is calculated as a value obtained by subtracting ahalf of the plate thickness t_(f1) of the flange 26 f 1 from the heighth_(w) of the main plate portion 26 w with the end part of the main plateportion 26 w not having the flange 26 f 1 and the flange 26 f 2, thatis, the end part on the lower side in the drawing surface of FIG. 5 asthe origin. A flange position of the flange 26 f 2 is calculated as avalue obtained by subtracting a half of the plate thickness t_(f2) ofthe flange 26 f 2 from the height h_(w) of the main plate portion 26 wwith the end part of the main plate portion 26 w not having the flange26 f 1 and the flange 26 f 2, that is, the end part on the lower side inthe drawing surface of FIG. 5 as the origin. In a case where the platethickness t_(f1) of the flange 26 f 1 is the same as the plate thicknesst_(f2) of the flange 26 f 2, a flange position of the flange 26 f 1 isthe same as a flange position of the flange 26 f 2.

The material 26 has the above-described configuration, and thus theentire height h of the material 26 is the same as the height h_(w) ofthe main plate portion 26 w. The entire length l of the material 26 isthe same as the largest length of the length l_(w) of the main plateportion 26 w, the length l_(f1) of the flange 26 f 1, and the lengthl_(f2) of the flange 26 f 2. The entire width w of the material 26 isthe same as a sum of the height h_(f1) of the flange 26 f 1 and theheight h_(f2) of the flange 26 f 2.

The material 26 has the flange 26 f 1 and the flange 26 f 2 of which aflange angle is 90 degrees on both surface sides of one end part of themain plate portion 26 w. Thus, the material 26 will be referred to as aT type since a shape of the side surface viewed from the directionorthogonal to the axial direction is similar to the alphabet characterT. The flange 26 f 1 and the flange 26 f 2 will also be referred to as Ttype flanges.

FIG. 6 is a side view illustrating a material 28 which is an example ofa material obtained through processing in the material processing system10. As illustrated in FIG. 6, the material 28 has a main plate portion28 w, a flange 28 f 1, a flange 28 f 2, and a cross part 28 m. An axialdirection in the material 28 is parallel to a direction orthogonal tothe drawing surface of FIG. 6. A height of the main plate portion 28 win the material 28, a length of the main plate portion 28 w, and a platethickness of the main plate portion 28 w are given the same referencesigns as those of the material 20, the material 22, the material 24, andthe material 26, and are respectively h_(w), l_(w), and t_(w). A heightof the flange 28 f 1 in the material 28, a length of the flange 28 f 1,and a plate thickness of the flange 28 f 1 are given the same referencesigns as those of the material 26, and are respectively h_(f1), l_(f1),and t_(f1). A height of the flange 28 f 2 in the material 28, a lengthof the flange 28 f 2, and a plate thickness of the flange 28 f 2 aregiven the same reference signs as those of the material 26, andrespectively h_(f2), l_(f2), and t_(f2). The length l_(w) of the mainplate portion 28 w, the length l_(f1) of the flange 28 f 1, and thelength l_(f2) of the flange 28 f 2 are not illustrated in FIG. 6.

A flange angle of the flange 28 f 1 in the material 28 is (90+θ1)degrees. Here, θ1 is a value greater than 0 degrees and smaller than 90degrees. A flange angle of the flange 28 f 2 in the material 28 is(90−θ2) degrees. Here, θ2 is a value greater than 0 degrees and smallerthan 90 degrees. The flange 28 f 1 is provided on one surface side ofthe main plate portion 28 w, specifically, on the right side in thedrawing surface of FIG. 6. The flange 28 f 2 is provided on the othersurface side of the main plate portion 28 w, specifically, on the leftside in the drawing surface of FIG. 6. In other words, in a case wherethe flange 28 f 1 and the flange 28 f 2 are viewed integrally in thematerial 28, the flange 28 f 1 and the flange 28 f 2 are provided onboth surface sides of the main plate portion 28 w.

Both of the flange 28 f 1 and the flange 28 f 2 are provided at one endpart of the main plate portion 28 w, specifically, at the upper end partin the drawing surface of FIG. 6. In other words, a flange position ofthe flange 28 f 1 is calculated as a value obtained by subtracting aproduct of a half of the plate thickness t_(f1) of the flange 28 f 1 andcos θ1 corresponding to a sine component of the flange angle from theheight h_(w) of the main plate portion 28 w with the end part of themain plate portion 28 w not having the flange 28 f 1 and the flange 28 f2, that is, the end part on the lower side in the drawing surface ofFIG. 6 as the origin. In other words, a flange position of the flange 28f 2 is calculated as a value obtained by subtracting a product of a halfof the plate thickness t_(f2) of the flange 28 f 2 and cos θ2corresponding to a cosine component of the flange angle from the heighth_(w) of the main plate portion 28 w with the end part of the main plateportion 28 w not having the flange 28 f 1 and the flange 28 f 2, thatis, the end part on the lower side in the drawing surface of FIG. 6 asthe origin. In a case where the plate thickness t_(f1) of the flange 28f 1 is the same as the plate thickness t_(f2) of the flange 28 f 2, andthe parameter θ1 for determining the flange angle of the flange 28 f 1is the same as the parameter θ2 for determining the flange angle of theflange 28 f 2, a flange position of the flange 28 f 1 is the same as aflange position of the flange 28 f 2.

The material 28 has the above-described configuration, and thus theentire height h of the material 28 is the same as a sum of the heighth_(w) of the main plate portion 28 w, and a product of the height h_(f1)of the flange 28 f 1 and sin θ1 corresponding to a sine component of theflange angle. The entire length l of the material 28 is the same as thelargest length of the length l_(w) of the main plate portion 28 w, thelength l_(f1) of the flange 28 f 1, and the length l_(f2) of the flange28 f 2. The entire width w of the material 28 is the same as a sum of aproduct of the height h_(f1) of the flange 28 f 1 and cos θ1corresponding to a cosine component of the flange angle, a product of ahalf of the plate thickness t_(f1) of the flange 28 f 1 and sin θ1corresponding to a sine component of the flange angle, a product of theheight h_(f2) of the flange 28 f 2 and cos θ2 corresponding to a cosinecomponent of the flange angle, and a product of a half of the platethickness t_(f2) of the flange 28 f 2 and sin θ2 corresponding to a sinecomponent of the flange angle.

The material 28 is changed from 90 degrees to (90+θ1) and (90−θ2)degrees in terms of a flange angle with respect to the material 26, andis classified as a T type in the same manner as the material 26. Theflange 28 f 1 and the flange 28 f 2 are classified as T type flanges.

FIG. 7 is a side view illustrating a material 32 which is an example ofa material obtained through processing in the material processing system10. As illustrated in FIG. 7, the material 32 has a main plate portion32 w, a flange 32 f, and a cross part 32 m. An axial direction in thematerial 32 is parallel to a direction orthogonal to the drawing surfaceof FIG. 7. A height of the main plate portion 32 w in the material 32, alength of the main plate portion 32 w, and a plate thickness of the mainplate portion 32 w are given the same reference signs as those of thematerial 20, the material 22, the material 24, the material 26, and thematerial 28, and are respectively h_(w), l_(w), and t_(w). A height ofthe flange 32 f 1 in the material 32, a length of the flange 32 f 1, anda plate thickness of the flange 32 f 1 are given the same referencesigns as those of the material 22 and the material 24, and arerespectively h_(f), l_(f), and t_(f). The length l_(w) of the main plateportion 32 w, and the length l_(f) of the flange 32 f are notillustrated in FIG. 7.

A flange angle of the flange 32 f in the material 32 is 90 degrees. Theflange 32 f is provided on one surface side of the main plate portion 32w, specifically, on the right side in the drawing surface of FIG. 7. Theflange 32 f is provided at a position other than an end part of the mainplate portion 32 w. In other words, a flange position of the flange 32 fis calculated as a value smaller than the height h_(w) of the main plateportion 32 w with an end part of the main plate portion 32 w far fromthe flange 32 f, that is, the lower end part in the drawing surface ofFIG. 7 as the origin.

The material 32 has the above-described configuration, and thus theentire height h of the material 32 is the same as the height h_(w) ofthe main plate portion 32 w. The entire length l of the material 32 isthe same as a larger length of the length l_(w) of the main plateportion 32 w and the length l_(f) of the flange 32 f. The entire width wof the material 32 is the same as a sum of the half of the platethickness t_(w) of the main plate portion 32 w and the height h_(f) ofthe flange 32 f.

The material 32 has the flange 32 f of which a flange angle is 90degrees on one surface side other than the end parts of the main plateportion 32 w. Thus, the material 32 will be referred to as acounterclockwise-T type since a shape of the side surface viewed fromthe direction orthogonal to the axial direction is similar to a shape ofa T counterclockwise-rotated by 90 degrees (hereinafter, simply referredto as a counterclockwise-T). The flange 32 f will be referred to as acounterclockwise-T type flange.

FIG. 8 is a side view illustrating a material 34 which is an example ofa material obtained through processing in the material processing system10. As illustrated in FIG. 8, the material 34 has a main plate portion34 w, a flange 34 f, and a cross part 34 m. An axial direction in thematerial 34 is parallel to a direction orthogonal to the drawing surfaceof FIG. 8. A height of the main plate portion 34 w in the material 34, alength of the main plate portion 34 w, and a plate thickness of the mainplate portion 34 w are given the same reference signs as those of thematerial 20, the material 22, the material 24, the material 26, thematerial 28, and the material 32, and are respectively h_(w), l_(w), andt_(w). A height of the flange 34 f in the material 34, a length of theflange 34 f, and a plate thickness of the flange 34 f are given the samereference signs as those of the material 22, the material 24, and thematerial 32, and are respectively h_(f), l_(f), and t_(f). The lengthl_(w) of the main plate portion 34 w and the length l_(f) of the flange34 f are not illustrated in FIG. 8.

A flange angle of the flange 34 f in the material 34 is (90+θ) degrees.The flange 34 f is provided on one surface side of the main plateportion 34 w, specifically, on the right side in the drawing surface ofFIG. 8. The flange 34 f is provided at a position other than an end partof the main plate portion 34 w. In other words, a flange position of theflange 34 f is calculated as a value smaller than the height h_(w) ofthe main plate portion 34 w with an end part of the main plate portion34 w on the side on which an angle formed between the flange 34 f andthe main plate portion 34 w is an obtuse angle, that is, the lower endpart in the drawing surface of FIG. 8 as the origin.

The material 34 has the above-described configuration, and thus theentire height h of the material 34 is the same as a greater value of theheight h_(w) of the main plate portion 34 w, and a value obtained byadding a product of the height h_(f) of the flange 34 f and sin θcorresponding to a cosine component of the flange angle to a product ofa half of the plate thickness t_(f) of the flange 34 f and cos θcorresponding to a cosine component of the flange angle at the flangeposition. In other words, the entire height h of the material 34 is thesame as the height h_(w) of the main plate portion 34 w in a case wherethe flange 34 f does not protrude from one end from the main plateportion 34 w in the height direction, and is the same as a valueobtained by adding a product of the height h_(f) of the flange 34 f andsin θ corresponding to a sine component of the flange angle to a productof a half of the plate thickness t_(f) of the flange 34 f and cos θcorresponding to a cosine component of the flange angle at the flangeposition in a case where the flange 34 f protrudes from one end from themain plate portion 34 w in the height direction.

The entire length l of the material 34 is the same as a larger length ofthe length l_(w) of the main plate portion 34 w and the length l_(f) ofthe flange 34 f. The entire width w of the material 34 is the same as asum of a half of the plate thickness t_(w) of the main plate portion 34w, a product h_(f) cos θ of the height h_(f) of the flange 34 f and cosθ corresponding to a cosine component of the flange angle, and a productof a half of the plate thickness t_(f) of the flange 34 f and sin θcorresponding to a sine component of the flange angle.

The material 34 is changed from 90 degrees to (90+θ) degrees in terms ofa flange angle with respect to the material 32, and is classified as acounterclockwise-T type in the same manner as the material 32. Theflange 34 f is classified as a counterclockwise-T type flange.

FIG. 9 is a side view illustrating a material 36 which is an example ofa material obtained through processing in the material processing system10. As illustrated in FIG. 9, the material 36 has a main plate portion36 w, a flange 36 f 1, a flange 36 f 2, and a cross part 36 m. An axialdirection in the material 36 is parallel to a direction orthogonal tothe drawing surface of FIG. 9. A height of the main plate portion 36 win the material 36, a length of the main plate portion 36 w, and a platethickness of the main plate portion 36 w are given the same referencesigns as those of the material 20, the material 22, the material 24, thematerial 26, the material 28, the material 32, and the material 34, andare respectively h_(w), l_(w), and t_(w). A height of the flange 36 f 1in the material 36, a length of the flange 36 f 1, and a plate thicknessof the flange 36 f 1 are given the same reference signs as those of thematerial 26 and the material 28, and are respectively h_(f1), l_(f1),and t_(f1). A height of the flange 36 f 2 in the material 36, a lengthof the flange 36 f 2, and a plate thickness of the flange 36 f 2 aregiven the same reference signs as those of the material 26 and thematerial 28, and are respectively h_(f2), l_(f2) and t_(f2). The lengthl_(w) of the main plate portion 36 w, the length l_(f1) of the flange 36f 1, and the length l_(f2) of the flange 36 f 2 are not illustrated inFIG. 9.

A flange angle of the flange 36 f 1 in the material 36 is 90 degrees. Aflange angle of the flange 36 f 2 in the material 36 is 90 degrees. Theflange 36 f 1 is provided on one surface side of the main plate portion36 w, specifically, on the right side in the drawing surface of FIG. 9.The flange 36 f 2 is provided on the other surface side of the mainplate portion 36 w, specifically, on the left side in the drawingsurface of FIG. 9. In other words, in a case where the flange 36 f 1 andthe flange 36 f 2 are viewed integrally in the material 36, the flange36 f 1 and the flange 36 f 2 are provided on both surface sides of themain plate portion 36 w.

Both of the flange 36 f 1 and the flange 36 f 2 are provided atpositions other than end parts of the main plate portion 36 w. In otherwords, both of flange positions of the flange 36 f 1 and the flange 36 f2 are calculated as values smaller than the height h_(w) of the mainplate portion 36 w with an end part of the main plate portion 36 w farfrom the flange 36 f 1 and the flange 36 f 2, that is, the lower endpart in the drawing surface of FIG. 9 as the origin.

The material 36 has the above-described configuration, and thus theentire height h of the material 36 is the same as the height h_(w) ofthe main plate portion 36 w. The entire length l of the material 36 isthe same as the largest length of the length l_(w) of the main plateportion 36 w, the length l_(f1) of the flange 36 f 1, and the lengthl_(f2) of the flange 36 f 2. The entire width w of the material 36 isthe same as a sum of the height h_(f1) of the flange 36 f 1 and theheight h_(f2) of the flange 36 f 2.

The material 36 has the flange 36 f 1 and the flange 36 f 2 of which aflange angle is 90 degrees on both surface sides other than the endparts of the main plate portion 36 w. Thus, the material 36 will bereferred to as a “+” type since a shape of the side surface viewed fromthe direction orthogonal to the axial direction is similar to theoperator “+”. The flange 36 f 1 and the flange 36 f 2 will also bereferred to as “+” type flanges.

FIG. 10 is a side view illustrating a material 38 which is an example ofa material obtained through processing in the material processing system10. As illustrated in FIG. 10, the material 38 has a main plate portion38 w, a flange 38 f 1, a flange 38 f 2, and a cross part 38 m. An axialdirection in the material 38 is parallel to a direction orthogonal tothe drawing surface of FIG. 10. A height of the main plate portion 38 win the material 38, a length of the main plate portion 38 w, and a platethickness of the main plate portion 38 w are given the same referencesigns as those of the material 20, the material 22, the material 24, thematerial 26, the material 28, the material 32, the material 34, and thematerial 36, and are respectively h_(w), l_(w), and t_(w). A height ofthe flange 38 f 1 in the material 38, a length of the flange 38 f 1, anda plate thickness of the flange 38 f 1 are given the same referencesigns as those of the material 26, the material 28, and the material 36,and are respectively h_(f1), l_(f1), and t_(f1). A height of the flange38 f 2 in the material 38, a length of the flange 38 f 2, and a platethickness of the flange 38 f 2 are given the same reference signs asthose of the material 26, the material 28, and the material 36, and arerespectively h_(f2), l_(f2), and t_(f2). The length l_(w) of the mainplate portion 38 w, the length l_(f1) of the flange 38 f 1, and thelength l_(f2) of the flange 38 f 2 are not illustrated in FIG. 10.

A flange angle of the flange 38 f 1 in the material 38 is (90+θ1)degrees. Here, θ1 is a value greater than 0 degrees and smaller than 90degrees. A flange angle of the flange 38 f 2 in the material 38 is(90−θ2) degrees. Here, θ2 is a value greater than 0 degrees and smallerthan 90 degrees. The flange 38 f 1 is provided on one surface side ofthe main plate portion 38 w, specifically, on the right side in thedrawing surface of FIG. 10. The flange 38 f 2 is provided on the othersurface side of the main plate portion 38 w, specifically, on the leftside in the drawing surface of FIG. 10. In other words, in a case wherethe flange 38 f 1 and the flange 38 f 2 are viewed integrally in thematerial 38, the flange 38 f 1 and the flange 38 f 2 are provided onboth surface sides of the main plate portion 38 w.

Both of the flange 38 f 1 and the flange 38 f 2 are provided atpositions other than end parts of the main plate portion 38 w. In otherwords, both of flange positions of the flange 38 f 1 and the flange 38 f2 are calculated as values smaller than the height h_(w) of the mainplate portion 38 w with an end part of the main plate portion 38 w farfrom the flange 38 f 1 and the flange 38 f 2, that is, the lower endpart in the drawing surface of FIG. 10 as the origin.

The material 38 has the above-described configuration, and thus theentire height h of the material 38 is the same as the height h_(w) ofthe main plate portion 38 w in a case where the flange 38 f 1 does notprotrude in the height direction from one end part of the main plateportion 38 w, and the flange 38 f 2 does not protrude in the heightdirection from the other end part of the main plate portion 38 w. In acase where the flange 38 f 1 protrudes in the height direction from oneend part of the main plate portion 38 w, and the flange 38 f 2 does notprotrude in the height direction from the other end part of the mainplate portion 38 w, the entire height h of the material 38 is the sameas a value obtained by adding a product of the height h_(f1) of theflange 38 f 1 and sin θ1 corresponding to a sine component of the flangeangle to a half of the plate thickness t_(f1) of the flange 38 f 1 andcos θ1 corresponding to a cosine component of the flange angle at theflange position from the end part of the main plate portion 38 w on theside on which an angle formed between the flange 38 f 1 and the mainplate portion 38 w is an obtuse angle. In a case where the flange 38 f 1does not protrude in the height direction from one end part of the mainplate portion 38 w, and the flange 38 f 2 protrudes in the heightdirection from the other end part of the main plate portion 38 w, theentire height h of the material 38 is the same as a value obtained byadding a product of the height h_(f2) of the flange 38 f 2 and sin θ2corresponding to a sine component of the flange angle to a half of theplate thickness t_(f2) of the flange 38 f 2 and cos θ2 corresponding toa cosine component of the flange angle at the flange position from theend part of the main plate portion 38 w on the side on which an angleformed between the flange 38 f 2 and the main plate portion 38 w is anobtuse angle. Since the main plate portion 38 w is a portion including asurface element including a straight line corresponding to the longestdistance between two points, there is no case where the flange 38 f 1protrudes in the height direction from one end part of the main plateportion 38 w, and the flange 38 f 2 protrudes in the height directionfrom the other end part of the main plate portion 38 w.

The entire length l of the material 38 is the same as the largest lengthof the length l_(w) of the main plate portion 38 w, the length l_(f1) ofthe flange 38 f 1, and the length l_(f2) of the flange 38 f 2. Theentire width w of the material 38 is the same as a sum of a product ofthe height h_(f1) of the flange 38 f 1 and cos θ1 corresponding to acosine component of the flange angle, a product of a half of the platethickness t_(f1) of the flange 38 f 1 and sin θ1 corresponding to a sinecomponent of the flange angle, a product of the height h_(f2) of theflange 38 f 2 and cos θ2 corresponding to a cosine component of theflange angle, and a product of a half of the plate thickness t_(f2) ofthe flange 38 f 2 and sin θ2 corresponding to a sine component of theflange angle.

The material 38 is changed from 90 degrees to (90+θ1) and (90-θ2)degrees in terms of a flange angle with respect to the material 36, andis classified as a “+” type in the same manner as the material 36. Theflange 38 f 1 and the flange 38 f 2 are classified as “+” type flanges.

As mentioned above, the material 20, the material 22, the material 24,the material 26, the material 28, the material 32, the material 34, thematerial 36, and the material 38 have been described as examples ofmaterials obtained through processing in the material processing system10 with reference to FIGS. 2 to 10, but materials obtained throughprocessing in the material processing system 10 are not limited thereto,and include any tabular material which is formed to extend along anaxial direction, and has a main plate portion including the maximumsurface element in the material, and at least one flange which is formedto extend in the axial direction, and is provided to extend in adirection intersecting the maximum surface element from the main plateportion.

FIG. 11 is a sectional view illustrating a curved portion 41 which is anexample of a curved portion. FIG. 12 is a sectional view illustrating atapered portion 42 which is an example of a tapered portion. FIG. 13 isa sectional view illustrating a step portion 43 which is an example of astep portion. FIG. 14 is a sectional view illustrating a step portion 44which is an example of a step portion. As illustrated in FIG. 11, thecurved portion 41 is a portion in which a curve is formed in a plateexemplified by a main plate portion and a flange. In the curved portion41, a difference between the highest point and the lowest point of theportion in which the curve is formed is t_max. As illustrated in FIG.12, the tapered portion 42 is a portion in which a region where a platethickness gradually changes is formed in a plate exemplified by a mainplate portion and a flange. In the tapered portion 42, a plate thicknessof the thickest portion is t_max. As illustrated in FIG. 13, the stepportion 43 is a portion in which a region where a plate thicknesssuddenly changes is formed in a plate exemplified by a main plateportion and a flange. In the step portion 43, a plate thickness of thethickest portion is t_max. As illustrated in FIG. 14, the step portion44 is a portion in which a sudden bending is formed in a plateexemplified by a main plate portion and a flange. In the step portion44, a difference between the highest point and the lowest point of theportion in which the sudden bending is formed is t_max. Hereinafter,t_max in the curved portion 41 illustrated in FIG. 11, the taperedportion 42 illustrated in FIG. 12, the step portion 43 illustrated inFIG. 13, and the step portion 44 illustrated in FIG. 14 will be referredto as a thickness of the thickest part. A material obtained throughprocessing in the material processing system 10 may include not only theabove-described materials but also any one or a combination of thecurved portion 41 illustrated in FIG. 11, the tapered portion 42illustrated in FIG. 12, the step portion 43 illustrated in FIG. 13, andthe step portion 44 illustrated in FIG. 14. A material obtained throughprocessing in the material processing system 10 may include a change inthe height in a direction perpendicular to each surface.

All of the above-described materials obtained through processing in thematerial processing system 10 may be suitably used for aircraftcomponents exemplified by a stringer, a shear tie, and a frame.

Hereinafter, a description will be made of operations of the rawmaterial shape determination system 11 and the raw material shapedetermination program 15. FIG. 15 is a flowchart illustrating an exampleof a flow of a raw material shape determination method. The raw materialshape determination method is a processing method performed by thecontrol section 11 c reading and executing the raw material shapedetermination program 15 in the raw material shape determination system11. The raw material shape determination method will be described withreference to FIG. 15. The raw material shape determination methodincludes, as illustrated in FIG. 15, material information acquisitionstep S12, flange classification step S14, grip portion setting step S16,and raw material shape calculation step S18. Hereinafter, materialinformation acquisition step S12, flange classification step S14, gripportion setting step S16, and raw material shape calculation step S18will be respectively simply referred to as step S12, step S14, step S16,and step S18 as appropriate.

First, the control section 11 c acquires information regarding a shapeof a material (step S12). Specifically, the control section 11 cacquires design model information regarding a three-dimensional designmodel created for the material by using a computer aided design softwareexemplified by computer aided design (CAD).

Next, the control section 11 c classifies a shape of a flange on thebasis of the acquired information regarding the shape of the material(step S14). Specifically, for example, the control section 11 cclassifies the shape of the flange into the above-described L typeflange, T type flange, counterclockwise-T type flange, and “+” typeflange. In a case where there is no flange, the material isautomatically classified as the I type in step S14.

The flange classification step S14 will be described below in detail.FIG. 16 is a flowchart illustrating an example of a detailed flow offlange classification step S14. Flange classification step S14 includes,as illustrated in FIG. 16, flange position determination step S21,flange installation surface determination step S22, L type flangeclassification step S23, T type flange classification step S24, flangeinstallation surface determination step S26, counterclockwise-T typeflange classification step S27, and “+” type flange classification stepS28. Hereinafter, flange position determination step S21, flangeinstallation surface determination step S22, L type flangeclassification step S23, T type flange classification step S24, flangeinstallation surface determination step S26, counterclockwise-T typeflange classification step S27, and “+” type flange classification stepS28 will be respectively simply referred to as step S21, step S22, stepS23, step S24, step S26, step S27, and step S28 as appropriate.

In flange classification step S14, first, the control section 11 cdetermines whether or not a flange is provided at an end part withrespect to each flange included in the acquired information of the shapeof the material (step S21). In a case where the classification targetflange is provided at the end part (YES in step S21), the controlsection 11 c determines whether or not the classification target flangeis provided on only one side of a main plate portion in a platethickness direction of the main plate portion (step S22). Here, in stepS22, in a case where there is a flange on an opposite side to theclassification target flange such that a flange position thereof isadjacent within a predetermined distance, the control section 11 cdetermines that the flanges are provided on both sides, regards theflanges including the classification target flange as a single flange,and performs a process. On the other hand, in step S22, in a case wherethere is no flange on an opposite side to the classification targetflange such that a flange position thereof is adjacent within apredetermined distance, the control section 11 c determines that theclassification target flange is provided on only one side, and performsa process.

In a case where the classification target flange is provided at the endpart (Yes in step S21), and the classification target flange is providedon only one side (Yes in step S22), the control section 11 c classifiesthe classification target flange as an L type flange (step S23). In acase where the classification target flange is provided at the end part(Yes in step S21), and the classification target flanges are provided onboth sides (No in step S22), the control section 11 c classifies theclassification target flange as a T type flange (step S24).

In a case where the classification target flange is not provided at theend part (No in step S21), the control section 11 c determines whetheror not the classification target flange is provided on only one side(step S26). Step S26 is the same process as step S22.

In a case where the classification target flange is not provided at theend part (No in step S21), and the classification target flange isprovided on only one side (Yes in step S26), the control section 11 cclassifies the classification target flange as a counterclockwise-T typeflange (step S27). In a case where the classification target flange isnot provided at the end part (No in step S21), and the classificationtarget flanges re provided on both sides (No in step S26), the controlsection 11 c classifies the classification target flange as a “+” typeflange (step S28).

In a case where flange shape classification is completed with respect toall flanges included in the acquired information regarding the shape ofthe material, the control section 11 c finishes flange classificationstep S14.

Details of flange classification step S14 illustrated in FIG. 16 areonly examples, and other classification methods may be used. Forexample, a T type flange may be regarded as two L type flanges, and a“+” type flange may be regarded as two counterclockwise-T type flangessuch that flanges are classified into only the L type flange and thecounterclockwise-T type flange, and other types of flanges may beseparately provided, and classification may be performed.

Next, the control section 11 c sets a grip portion which is grippedduring processing of the material on the basis of the acquiredinformation regarding the shape of the material and flangeclassification information in flange classification step S14 (step S16).For example, the control section 11 c sets a grip portion to one endpart of the main plate portion. In a case where it is determined thatthe material is of an I type in step S14, a grip portion isautomatically set at one end part of the main plate portion in step S16.

Grip portion setting step S16 will be described below in detail. FIG. 17is a flowchart illustrating an example of a detailed flow of gripportion setting step S16. Grip portion setting step S16 includes, asillustrated in FIG. 17, first flange information determination step S31,second flange information determination step S32, first grip portionsetting step S33, second grip portion setting step S34, third flangeinformation determination step S36, third grip portion setting step S37,and fourth grip portion setting step S38. Hereinafter, first flangeinformation determination step S31, second flange informationdetermination step S32, first grip portion setting step S33, second gripportion setting step S34, third flange information determination stepS36, third grip portion setting step S37, and fourth grip portionsetting step S38 will be respectively simply referred to as step S31,step S32, step S33, step S34, step S36, step S37, and step S38 asappropriate.

In grip portion setting step S16, first, the control section 11 cdetermines whether or not the flange classification information inflange classification step S14 includes an L type flange or a T typeflange (step S31). In a case where the L type flange or the T typeflange is included (Yes in step S31), the control section 11 cdetermines whether or not the L type flange or the T type flange isprovided at only one end part of the main plate portion (step S32). In acase where there is no L type flange or T type flange (No in step S31),the control section 11 c determines whether or not a “+” type flange isincluded (step S36).

In a case where there is the L type flange or the T type flange (Yes instep S31), and the L type flange or the T type flange is provided atonly one end part of the main plate portion (Yes in step S32), thecontrol section 11 c is set a grip portion to an end part at which the Ltype flange or the T type flange is not provided (step S33), andfinishes grip portion setting step S16. In a case where there is the Ltype flange or the T type flange (Yes in step S31), and the L typeflange or the T type flange is provided at both end parts of the mainplate portion (No in step S32), the control section 11 c is set a gripportion to one end part of the main plate portion (step S34), andfinishes grip portion setting step S16. In step S34, for example, it maybe determined at which end part a grip portion is set on the basis of ashape of an L type flange or a T type flange provided at each end part.

In a case where there is no L type flange or T type flange (No in stepS31), and there is a “+” type flange (Yes in step S36), the controlsection 11 c sets a grip portion at an end part of the main plateportion far from the “+” type flange (step S37), and finishes gripportion setting step S16. In a case where there is no L type flange or Ttype flange (No in step S31), and there is no “+” type flange (No instep S36), the control section 11 c sets a grip portion at an end partof the main plate portion on the side on which and angle formed betweena counterclockwise-T type flange and the main plate portion is a rightangle or an obtuse angle (step S38), and finishes grip portion settingstep S16.

Next, the control section 11 c calculates a shape of a raw materialrequired for processing of the material on the basis of the acquiredinformation regarding the shape of the material, the flangeclassification information in flange classification step S14, and gripportion setting information in grip portion setting step S16 (step S18).Specifically, the control section 11 c determines a shape of a rawmaterial by setting an excess margin which is an outer peripheralmargin, a grip portion for gripping, and a cutting portion which is aportion for cutting a gap between the material obtained throughprocessing in the material processing system 10 and a grip portion v,with respect to the shape of the material.

Raw material shape calculation step S18 will be described below indetail. FIG. 18 is a flowchart illustrating an example of a detailedflow of raw material shape calculation step S18. Raw material shapecalculation step S18 includes, as illustrated in FIG. 18, main plateportion raw material height calculation step S41, main plate portion rawmaterial length calculation step S42, main plate portion raw materialplate thickness calculation step S43, flange raw material heightcalculation step S45, flange raw material length calculation step S46,flange raw material plate thickness calculation step S47, flange rawmaterial plate thickness correction step S48, raw material heightcalculation step S51, raw material length calculation step S52, rawmaterial width calculation step S53, and correction step S55.Hereinafter, main plate portion raw material height calculation stepS41, main plate portion raw material length calculation step S42, mainplate portion raw material plate thickness calculation step S43, flangeraw material height calculation step S45, flange raw material lengthcalculation step S46, flange raw material plate thickness calculationstep S47, flange raw material plate thickness correction step S48, rawmaterial height calculation step S51, raw material length calculationstep S52, raw material width calculation step S53, and correction stepS55 will be respectively simply referred to as step S41, step S42, stepS43, step S45, step S46, step S47, step S48, step S51, step S52, stepS53, and step S55 as appropriate.

In raw material shape calculation step S18, first, the control section11 c calculates a main plate portion raw material height which is a sizeof the main plate portion along a height direction in a main plate rawmaterial portion which is included in a raw material and will beprocessed to the main plate portion (step S41). Specifically, thecontrol section 11 c calculates the main plate portion raw materialheight on the basis of the height h_(w) of the main plate portion, asize of the excess margin, a height of the grip portion, and a height ofthe cutting portion. For example, the control section 11 c calculatesthe main plate portion raw material height as a sum of the height h_(w)of the main plate portion, the size of the excess margin, the height ofthe grip portion, and the height of the cutting portion.

The control section 11 c calculates a main plate portion raw materiallength which is a size of the main plate portion along a lengthdirection in the main plate raw material portion (step S42).Specifically, the control section 11 c calculates the main plate portionraw material length on the basis of the length l_(w) of the main plateportion and the size of the excess margin. For example, the controlsection 11 c calculates the main plate portion raw material length as asum of the length l_(w) of the main plate portion, an excess marginprovided on one side of the main plate portion in the length direction,and an excess margin provided on the other side of the main plateportion in the length direction, that is, a sum of the length l_(w) ofthe main plate portion and twice the size of the excess margin.

The control section 11 c calculates a main plate portion raw materialplate thickness which is a size of the main plate portion along a platethickness direction in the main plate raw material portion (step S43).Specifically, the control section 11 c calculates a main plate portionraw material plate thickness on the basis of the main plate portion rawmaterial height calculated in step S41, the height of the grip portion,and a parameter based on a substance. For example, the control section11 c calculates the main plate portion raw material plate thickness as alength equal to or more than a product of a value obtained bysubtracting the height of the grip portion from the main plate portionraw material height, and the parameter based on the substance. Here, theparameter based on the substance is a value which is predefinedaccording to the rigidity of the substance, and is, for example, ⅕ in acase of aluminum which is suitably used for an aircraft component.

Step S41, step S42, and step S43 are all processes of calculating a sizeof the main plate raw material portion. In the present embodiment, theprocesses are performed in an order of step S41, step S42, and step S43,but are not limited thereto, the processes may be performed in an orderstep S42, step S41, and step S43, and the processes may be performed inan order step S41, step S43, and step S42. However, step S43 is aprocess using the main plate portion raw material height calculated instep S41, and is thus performed after step S41.

The control section 11 c calculates a flange raw material height whichis a size of the flange in a height direction along a flange rawmaterial portion which is included in a raw material and will beprocessed to the flange (step S45). Specifically, the control section 11c calculates the flange raw material height on the basis of the heighth_(f) of the flange, a size of an excess margin, and a flange angle. Forexample, the control section 11 c calculates the flange raw materialheight as a sum of the height h_(f) of the flange, and a product of thesize of the excess margin and cos θ corresponding to a cosine componentof the flange angle.

The control section 11 c calculates a flange raw material length whichis a size of the flange along a length direction in the flange rawmaterial portion (step S46). Specifically, the control section 11 ccalculates the flange raw material length on the basis of the lengthl_(f) of the flange and a size of an excess margin. For example, thecontrol section 11 c calculates the flange material length as a sum ofthe length l_(f) of the flange, an excess margin provided on one side ofthe flange in the length direction, and an excess margin provided on theother side of the flange in the length direction, that is, a sum of thelength l_(f) of the flange and twice the size of the excess margin.

The control section 11 c calculates a flange raw material platethickness which is a size of the flange along a plate thicknessdirection in the flange raw material portion (step S47). Specifically,the control section 11 c calculates the flange raw material platethickness on the basis of the flange raw material height calculated instep S45, the main plate portion raw material plate thickness calculatedin step S43, and the parameter based on the substance. For example, thecontrol section 11 c calculates the flange raw material plate thicknessas a length equal to or more than a product of a value obtained bysubtracting a product of a half of the main plate portion raw materialplate thickness calculated in step S43 and cos θ corresponding to acosine component of the flange angle from the flange raw material heightcalculated in step S45, and the parameter based on the substance.

The control section 11 c corrects the flange raw material platethickness which is a size of the flange along the plate thicknessdirection in the flange raw material portion (step S48). Specifically,in a case where a size of the flange raw material portion is calculatedwith respect to the flange classified as an L type flange in step S23 orthe flange classified as a T type flange in step S24, the controlsection 11 c secures an excess margin on the end part side of the mainplate portion by correcting the outer peripheral margin on the end partside of the main plate portion to a size of the excess margin andcorrecting the flange raw material plate thickness calculated in stepS47 in accordance therewith in the flange raw material portion.

Step S45, step S46, step S47, and step S48 are all processes ofcalculating a size of the flange raw material portion. In the presentembodiment, the processes are performed in an order of step S45, stepS46, step S47, and step S48, but are not limited thereto, and step S46may be performed in any order as long as an order of step S45, step S47,and step S48 is kept. In a case where step S47 and step S48 areperformed after step S43, a processing order thereof may be replacedwith step S41, step S42, and step S43 as appropriate.

With respect to a cross raw material portion which is included in a rawmaterial and will be processed to a cross part, the control section 11 ccalculates, as appropriate, a size and a shape thereof causing the mainplate raw material portion and the flange raw material portion to besmoothly connected to each other on the basis of the calculated size andshape of the main plate raw material portion and the calculated size andshape of the flange raw material portion.

The control section 11 c calculates a raw material height which is asize of the raw material along the height direction of the main plateportion (step S51). Specifically, the control section 11 c calculatesthe raw material height on the basis of the flange position and theflange angle determined in step S21, the main plate portion raw materialheight calculated in step S41, the flange raw material height calculatedin step S45, and the flange raw material plate thickness calculated instep S47 and corrected in step S48. For example, in a case where theflanges do not protrude in the height direction from both end parts ofthe main plate portion, the control section 11 c calculates the rawmaterial height as a value equal to the main plate portion raw materialheight. In a case where the flange raw material portion protrudes fromone end part of the main plate raw material portion in the heightdirection, the control section 11 c calculates the raw material heightby adding the height of the grip portion and the height of the cuttingportion to a value for a flange which protrude most, for example, aflange causing a sum of the flange position, a product of the main plateportion raw material height and sin θ corresponding to a sine componentof the flange angle, and a product of the flange raw material platethickness and cos θ corresponding to a cosine component of the flangeangle, to be the maximum. In a case where flanges protrude from both endparts of the main plate portion in the height direction, the controlsection 11 c calculates the raw material height by calculating a sum ofthe flange position, a product of the main plate portion raw materialheight and sin θ corresponding to a sine component of the flange angle,and a product of the flange raw material plate thickness and cos θcorresponding to a cosine component of the flange angle, subtracting themain plate portion raw material height from the sum, and adding theheight of the grip portion and the height of the cutting portion to aresult thereof, with respect to each flange which protrudes most fromone end part side and the other end part side.

The control section 11 c calculates a raw material length which is asize along the length direction of the main plate portion in the rawmaterial (step S52).

Specifically, the control section 11 c calculates the raw materiallength on the basis of the main plate portion raw material lengthcalculated in step S42 and the flange raw material length calculated instep S46. For example, the control section 11 c calculates the rawmaterial length as a larger length of the main plate portion rawmaterial length and the flange raw material length.

The control section 11 c calculates a raw material width which is a sizealong the plate thickness direction of the main plate portion in the rawmaterial (step S53). Specifically, the control section 11 c calculatesthe raw material width on the basis of the flange angle, the main plateportion raw material plate thickness calculated in step S43, the flangeraw material height calculated in step S45, and the flange raw materialplate thickness calculated in step S47 and corrected in step S48. Forexample, in a case where a flange is provided on one side of the mainplate portion in the plate thickness direction of the main plateportion, the control section 11 c calculates the raw material width byadding a half value of the main plate portion raw material platethickness to a value for a flange which protrude most in the platethickness direction of the main plate portion, for example, a flangecausing a sum of the flange position, a product of the flange rawmaterial height and cos θ corresponding to a cosine component of theflange angle, and a product of the flange raw material plate thicknessand sin θ corresponding to a sine component of the flange angle, to bethe maximum. In a case where flanges are provided on both sides of themain plate portion in the plate thickness direction of the main plateportion, the control section 11 c calculates a sum of a product of theflange raw material height and cos θ corresponding to a cosine componentof the flange angle and a product of the flange raw material platethickness and sin θ corresponding to a sine component of the flangeangle, and calculates the raw material width as the sum, with respect tofor each flange which protrudes most from one end part and the other endpart of the main plate portion in the plate thickness direction.

Step S51, step S52, and step S53 are all processes of calculating a sizeof the raw material. In the present embodiment, the processes areperformed in an order of step S51, step S52, and step S53, but are notlimited thereto, and the three processes may be performed in any order.However, step S51 is performed after step S41, step S45, step S47, andstep S48. Step S52 is performed after step S42 and step S46. Step S53 isperformed after step S43, step S45, step S47, and step S48.

In a case where the main plate portion or the flange includes any one ora combination of the curved portion 41 illustrated in FIG. 11, thetapered portion 42 illustrated in FIG. 12, the step portion 43illustrated in FIG. 13, and the step portion 44 illustrated in FIG. 14,the control section 11 c corrects the plate thickness t_(w) of the mainplate portion or the plate thickness t_(f) of the flange correspondingthereto and corrects the main plate portion raw material plate thicknessof the main plate raw material portion or the flange raw material platethickness of the flange raw material portion corresponding thereto, soas to correct a size and a shape of the raw material (step S55).Specifically, the control section 11 c corrects a size and a shape ofthe raw material by using the thickness t_max of the thickest portion ofthe main plate portion or the flange including any one or a combinationof the curved portion 41, the tapered portion 42, the step portion 43,and the step portion 44 as the plate thickness t_(w) of the main plateportion or the plate thickness t_(f) of the flange. In a case where theprocess in step S55 is performed, raw material shape calculation stepS18 is finished, and a series of flows of the raw material shapedetermination method is finished.

Step S55 is performed last in raw material shape calculation step S18 inthe present embodiment, but is not limited thereto, and may be performedas appropriate in main plate portion raw material plate thicknesscalculation step S43 or flange raw material plate thickness calculationstep S47, and may be performed as appropriate during calculation of asize and a shape of a raw material.

In the raw material shape determination system 11, the raw materialshape determination program 15, and raw material shape determinationmethod processed thereby according to the present embodiment, thecontrol section 11 c performs flange classification step S14 and gripportion setting step S16 such that a grip portion is set at an end partof a main plate portion according to a flange. Thus, in the raw materialshape determination system 11, the raw material shape determinationprogram 15, and raw material shape determination method processedthereby, it is possible to provide a raw material shape which is assmall as possible, required to process a material, that is, to provide araw material shape enabling a material to be processed at low cost,compared with the related art.

In the raw material shape determination system 11, the raw materialshape determination program 15, and raw material shape determinationmethod processed thereby according to the present embodiment, a gripportion is set at an end part of a main plate portion farthest from aflange, and thus it is possible to provide a single grip portion whichis as small as possible, required to process a material, compared withthe related art. Thus, In the raw material shape determination system11, the raw material shape determination program 15, and raw materialshape determination method processed thereby, it is possible to providea raw material shape causing residual stress accumulated in a materialto be remarkably reduced during processing of the material. Therefore,in the raw material shape determination system 11, the raw materialshape determination program 15, and raw material shape determinationmethod processed thereby, it is possible to provide a raw material shapeenabling a material to be processed with high accuracy.

In the raw material shape determination system 11, the raw materialshape determination program 15, and raw material shape determinationmethod processed thereby according to the present embodiment, thecontrol section 11 c performs flange classification step S14 so as toclassify a flange into an L type flange, a T type flange, acounterclockwise-T type flange, and a “+” type flange. Thus, in the rawmaterial shape determination system 11, the raw material shapedetermination program 15, and raw material shape determination methodprocessed thereby, it is possible to more accurately set a grip portionin the subsequent grip portion setting step S16. Therefore, in the rawmaterial shape determination system 11, the raw material shapedetermination program 15, and raw material shape determination methodprocessed thereby, it is possible to provide a raw material shapecausing a material to be processed at low cost. In the raw materialshape determination system 11, the raw material shape determinationprogram 15, and raw material shape determination method processedthereby, it is possible to provide a raw material shape causing residualstress accumulated in a material to be remarkably reduced duringprocessing of the material and thus to provide the raw material shapeenabling the material to be processed with higher accuracy.

In the raw material shape determination system 11, the raw materialshape determination program 15, and raw material shape determinationmethod processed thereby according to the present embodiment, gripportion setting step S16 is performed such that a grip portion is set atan end part of a main plate portion farthest from a flange. Thus, in theraw material shape determination system 11, the raw material shapedetermination program 15, and raw material shape determination methodprocessed thereby, it is possible to provide a raw material shapecausing residual stress accumulated in a material to be more remarkablyreduced during processing of the material and thus to provide the rawmaterial shape enabling the material to be processed with higheraccuracy.

In the raw material shape determination system 11, the raw materialshape determination program 15, and raw material shape determinationmethod processed thereby according to the present embodiment, a size ofa main plate raw material portion is calculated, a size of a flange rawmaterial portion is calculated, and a size of a raw material iscalculated, in raw material shape calculation step S18. Thus, it ispossible to calculate a raw material shape suitable for processing of amaterial with high accuracy.

In the raw material shape determination system 11, the raw materialshape determination program 15, and raw material shape determinationmethod processed thereby according to the present embodiment, a platethickness of a main plate raw material portion and a plate thickness ofa flange raw material portion are calculated by using a parameter basedon a substance, predefined according to the rigidity of the substance.Thus, even in a case where a grip portion to be gripped duringprocessing is small, it is possible to provide a raw material shapecausing a material or a raw material to be stably processed with highaccuracy.

Hereinafter, a description will be made of a shape of a raw materialwhich is calculated and determined according to the raw material shapedetermination system 11, the raw material shape determination program15, and raw material shape determination method processed thereby in thepresent embodiment, on the basis of information regarding shapes of thematerial 20, the material 22, the material 24, the material 26, thematerial 28, the material 32, the material 34, the material 36, and thematerial 38.

FIG. 19 is a side view illustrating a raw material 50 which is anexample of a raw material determined according to the raw material shapedetermination method. The raw material 50 is calculated and determinedon the basis of the information regarding the shape of the material 20.As illustrated in FIG. 19, the raw material 50 has a main plate rawmaterial portion 50W. The main plate raw material portion 50W is aportion to be processed to the main plate portion 20 w. A height H_(w)of the main plate raw material portion 50W, which is the main plate rawmaterial portion height calculated in main plate portion raw materialheight calculation step S41, is a sum of the height h_(w) of the mainplate portion 20 w, a size of an excess margin e, a height of a gripportion v, and a height of a cutting portion c, and is the same as a rawmaterial height H calculated in raw material height calculation stepS51. A length L_(w) of the main plate raw material portion 50W, which isthe main plate portion raw material length calculated in main plateportion raw material length calculation step S42, is a sum of the lengthl_(w) of the main plate portion 20 w and twice the size of the excessmargin e, and is the same as a raw material length L calculated in rawmaterial length calculation step S52. A plate thickness T_(w) of themain plate raw material portion 50W, which is the main plate portion rawmaterial plate thickness calculated in main plate portion raw materialplate thickness calculation step S43, is a length equal to or more thana product of a value obtained by subtracting the height of the gripportion v from the height H_(w) of the main plate raw material portion50W, and the parameter based on the substance, and is the same as a rawmaterial width W calculated in raw material width calculation step S53.

In addition to the raw material 50 illustrated in FIG. 19, in each ofall raw materials described below, the height H_(w) of a main plate rawmaterial portion is the main plate portion raw material heightcalculated in main plate portion raw material height calculation stepS41, the length L_(w) of the main plate raw material portion is the mainplate portion raw material length calculated in main plate portion rawmaterial length calculation step S42, and the plate thickness T_(w) ofthe main plate raw material portion is the main plate portion rawmaterial plate thickness calculated in main plate portion raw materialplate thickness calculation step S43. Similarly, the raw material heightH is calculated in raw material height calculation step S51, the rawmaterial length L is calculated in raw material length calculation stepS52, and the raw material width W is calculated in raw material widthcalculation step S53.

FIG. 20 is a side view illustrating a raw material 52 which is anexample of a raw material determined according to the raw material shapedetermination method. The raw material 52 is calculated and determinedon the basis of the information regarding the shape of the material 22.The raw material 52 includes, as illustrated in FIG. 20, a main plateraw material portion 52W, a flange raw material portion 52F, and a crossraw material portion 52M. The main plate raw material portion 52W is aportion to be processed to the main plate portion 22 w. The flange rawmaterial portion 52F is a portion to be processed to the flange 22 f.The cross raw material portion 52M is a portion to be processed to thecross part 22 m.

The height H_(w) of the main plate raw material portion 52W is a sum ofthe height h_(w) of the main plate portion 22 w, a size of the excessmargin e, a height of the grip portion v, and a height of the cuttingportion c. Although not illustrated in FIG. 20, the length L_(w) of themain plate raw material portion 52W is a sum of the length l_(w) of themain plate portion 22 w and twice the size of the excess margin e. Theplate thickness T_(w) of the main plate raw material portion 52W is alength equal to or more than a product of a value obtained bysubtracting the height of the grip portion v from the height H_(w) ofthe main plate raw material portion 52W, and the parameter based on thesubstance.

The height H_(f) of the flange raw material portion 52F is the flangeraw material height calculated in flange raw material height calculationstep S45, and is a sum of the height h_(f) of the flange 22 f and thesize of the excess margin e. The length L_(f) of the flange raw materialportion 52F is the flange raw material length calculated in flange rawmaterial length calculation step S46, and is a sum of the length l_(f)of the flange 22 f and twice the size of the excess margin e althoughnot illustrated in FIG. 20. The plate thickness T_(f) of the flange rawmaterial portion 52F is the flange raw material plate thickness which iscalculated in flange raw material plate thickness calculation step S47and is corrected in flange raw material plate thickness correction stepS48 as necessary, and is a length equal to or more than a product of avalue obtained by subtracting a half of the plate thickness T_(w) of themain plate raw material portion 52W from the height H_(f) of the flangeraw material portion 52F, and the parameter based on the substance. Theflange 22 f is provided at the end part of the main plate portion 22 w,and thus the plate thickness T_(f) of the flange raw material portion52F secures the excess margin e on the end part side of the main plateportion 22 w.

The cross raw material portion 52M has a size and a shape causing thesize and the shape of the main plate raw material portion 52W to besmoothly connected to the size and the shape of the flange raw materialportion 52F.

Since the flange 22 f does not protrude in the height direction fromboth end parts of the main plate portion 22 w, the height H of the rawmaterial 52 is the same as the height H_(w) of the main plate rawmaterial portion 52W. Although not illustrated in FIG. 20, the length Lof the raw material 52 is a larger length of the length L_(w) of themain plate raw material portion 52W and the length L_(f) of the flangeraw material portion 52F. Since the flange 22 f is provided on only oneside of the main plate portion 22 w in the direction of the platethickness t_(w) of the main plate portion 22 w, the width W of the rawmaterial 52 is a sum of the height H_(f) of the flange raw materialportion 52F and a value of a half of the plate thickness T_(w) of themain plate raw material portion 52W.

In addition to the raw material 52 illustrated in FIG. 20, in each ofall raw materials described below, the height H_(f) of a flange rawmaterial portion is the flange raw material height calculated in flangeraw material height calculation step S45, the length L_(f) of the flangeraw material portion is the flange raw material length calculated inflange raw material length calculation step S46, and the plate thicknessT_(f) of the flange raw material portion is the flange raw materialplate thickness which is calculated in flange raw material platethickness calculation step S47 and is corrected in flange raw materialplate thickness correction step S48 as necessary.

FIG. 21 is a side view illustrating a raw material 54 which is anexample of a raw material determined according to the raw material shapedetermination method. The raw material 54 is calculated and determinedon the basis of the information regarding the shape of the material 24.The raw material 54 includes, as illustrated in FIG. 21, a main plateraw material portion 54W, a flange raw material portion 54F, and a crossraw material portion 54M. The main plate raw material portion 54W is aportion to be processed to the main plate portion 24 w. The flange rawmaterial portion 54F is a portion to be processed to the flange 24 f.The cross raw material portion 54M is a portion to be processed to thecross part 24 m.

The height H_(w) of the main plate raw material portion 54W is a sum ofthe height h_(w) of the main plate portion 24 w, a size of the excessmargin e, a height of the grip portion v, and a height of the cuttingportion c. Although not illustrated in FIG. 21, the length L_(w) of themain plate raw material portion 54W is a sum of the length l_(w) of themain plate portion 24 w and twice the size of the excess margin e. Theplate thickness T_(w) of the main plate raw material portion 54W is alength equal to or more than a product of a value obtained bysubtracting the height of the grip portion v from the height H_(w) ofthe main plate raw material portion 54W, and the parameter based on thesubstance.

The height H_(f) of the flange raw material portion 54F is a sum of theheight h_(f) of the flange 24 f, and a product of the size of the excessmargin e and cos θ corresponding to a cosine component of the flangeangle. The length L_(f) of the flange raw material portion 54F is a sumof the length l_(f) of the flange 24 f and twice the size of the excessmargin e although not illustrated in FIG. 21. The plate thickness T_(f)of the flange raw material portion 54F is a length equal to or more thana product of a value obtained by subtracting a product of a half of theplate thickness T_(w) of the main plate raw material portion 54W and cosθ corresponding to a cosine component of the flange angle from theheight H_(f) of the flange raw material portion 54F, and the parameterbased on the substance. The flange 24 f is provided at the end part ofthe main plate portion 24 w, and thus the plate thickness T_(f) of theflange raw material portion 54F secures the excess margin e on the endpart side of the main plate portion 24 w.

The cross raw material portion 54M has a size and a shape causing thesize and the shape of the main plate raw material portion 54W to besmoothly connected to the size and the shape of the flange raw materialportion 54F.

Since the flange 24 f protrudes in the height direction from one endpart of the main plate portion 24 w, the height H of the raw material 54is a value obtained by adding a height of the grip portion v and aheight of the cutting portion c to a sum of a flange position, a productof the height H_(w) of the main plate raw material portion 54W and sin θcorresponding to a sine component of the flange angle, and a product ofthe plate thickness T_(f) of the flange raw material portion 54F and cosθ corresponding to a cosine component of the flange angle. Although notillustrated in FIG. 21, the length L of the raw material 54 is a largerlength of the length L_(w) of the main plate raw material portion 54Wand the length L_(f) of the flange raw material portion 54F. Since theflange 24 f is provided on only one side of the main plate portion 24 win the direction of the plate thickness t_(w) of the main plate portion24 w, the width W of the raw material 54 is a sum of a product of theheight H_(f) of the flange raw material portion 54F and cos θcorresponding to a cosine component of the flange angle, a product ofthe plate thickness T_(f) of the flange raw material portion 54F and sinθ corresponding to a sine component of the flange angle, and a value ofa half of the plate thickness T_(w) of the main plate raw materialportion 54W.

FIG. 22 is a side view illustrating a raw material 56 which is anexample of a raw material determined according to the raw material shapedetermination method. The raw material 56 is calculated and determinedon the basis of the information regarding the shape of the material 26.The raw material 56 includes, as illustrated in FIG. 22, a main plateraw material portion 56W, a flange raw material portion 56F1, a flangeraw material portion 56F2, and a cross raw material portion 56M. Themain plate raw material portion 56W is a portion to be processed to themain plate portion 26 w. The flange raw material portion 56F1 is aportion to be processed to the flange 26 f 1. The flange raw materialportion 56F2 is a portion to be processed to the flange 26 f 2. Thecross raw material portion 56M is a portion to be processed to the crosspart 26 m.

The height H_(w) of the main plate raw material portion 56W is a sum ofthe height h_(w) of the main plate portion 26 w, a size of the excessmargin e, a height of the grip portion v, and a height of the cuttingportion c. Although not illustrated in FIG. 22, the length L_(w) of themain plate raw material portion 56W is a sum of the length l_(w) of themain plate portion 26 w and twice the size of the excess margin e. Theplate thickness T_(w) of the main plate raw material portion 56W is alength equal to or more than a product of a value obtained bysubtracting the height of the grip portion v from the height H_(w) ofthe main plate raw material portion 56W, and the parameter based on thesubstance.

The height H_(f1) of the flange raw material portion 56F1 is a sum ofthe height h_(f1) of the flange 26 f 1 and the size of the excess margine. The length L_(f1) of the flange raw material portion 56F1 is a sum ofthe length l_(f1) of the flange 26 f 1 and twice the size of the excessmargin e although not illustrated in FIG. 22. The plate thickness T_(f1)of the flange raw material portion 56F1 is a length equal to or morethan a product of a value obtained by subtracting a half of the platethickness T_(w) of the main plate raw material portion 56W from theheight H_(f1) of the flange raw material portion 56F1, and the parameterbased on the substance. The flange 26 f 1 is provided at the end part ofthe main plate portion 26 w, and thus the plate thickness T_(f1) of theflange raw material portion 56F1 secures the excess margin e on the endpart side of the main plate portion 26 w.

The height H_(f2) of the flange raw material portion 56F2 is a sum ofthe height h_(f2) of the flange 26 f 2 and the size of the excess margine. The length L_(f2) of the flange raw material portion 56F2 is a sum ofthe length l_(f2) of the flange 26 f 2 and twice the size of the excessmargin e although not illustrated in FIG. 22. The plate thickness T_(f2)of the flange raw material portion 56F2 is a length equal to or morethan a product of a value obtained by subtracting a half of the platethickness T_(w) of the main plate raw material portion 56W from theheight H_(f2) of the flange raw material portion 56F2, and the parameterbased on the substance. The flange 26 f 2 is provided at the end part ofthe main plate portion 26 w, and thus the plate thickness T_(f2) of theflange raw material portion 56F2 secures the excess margin e on the endpart side of the main plate portion 26 w.

The cross raw material portion 56M has a size and a shape causing thesize and the shape of the main plate raw material portion 56W, the sizeand the shape of the flange raw material portion 56F1, and the size andthe shape of the flange raw material portion 56F2 to be smoothlyconnected to each other.

Since the flange 26 f 1 and the flange 26 f 2 do not protrude in theheight direction from both end parts of the main plate portion 26 w, theheight H of the raw material 56 is the same as the height H_(w) of themain plate raw material portion 56W. Although not illustrated in FIG.22, the length L of the raw material 56 is the largest length among thelength L_(w) of the main plate raw material portion 56W, the lengthL_(f1) of the flange raw material portion 56F1, and the length L_(f2) ofthe flange raw material portion 56F2. Since the flange 26 f 1 and theflange 26 f 2 are provided on both sides of the main plate portion 26 win the direction of the plate thickness t_(w) of the main plate portion26 w, the width W of the raw material 56 is a sum of the height H_(f1)of the flange raw material portion 56F1 and height H_(f2) of the flangeraw material portion 56F2.

FIG. 23 is a side view illustrating a raw material 58 which is anexample of a raw material determined according to the raw material shapedetermination method. The raw material 58 is calculated and determinedon the basis of the information regarding the shape of the material 28.The raw material 58 includes, as illustrated in FIG. 23, a main plateraw material portion 58W, a flange raw material portion 58F1, a flangeraw material portion 58F2, and a cross raw material portion 58M. Themain plate raw material portion 58W is a portion to be processed to themain plate portion 28 w. The flange raw material portion 58F1 is aportion to be processed to the flange 28 f 1. The flange raw materialportion 58F2 is a portion to be processed to the flange 28 f 2. Thecross raw material portion 58M is a portion to be processed to the crosspart 28 m.

The height H_(w) of the main plate raw material portion 58W is a sum ofthe height h_(w) of the main plate portion 28 w, a size of the excessmargin e, a height of the grip portion v, and a height of the cuttingportion c. Although not illustrated in FIG. 23, the length L_(w) of themain plate raw material portion 58W is a sum of the length l_(w) of themain plate portion 28 w and twice the size of the excess margin e. Theplate thickness T_(w) of the main plate raw material portion 58W is alength equal to or more than a product of a value obtained bysubtracting the height of the grip portion v from the height H_(w) ofthe main plate raw material portion 58W, and the parameter based on thesubstance.

The height H_(f1) of the flange raw material portion 58F1 is a sum ofthe height h_(f1) of the flange 28 f 1, and a product of the size of theexcess margin e and cos θ1 corresponding to a cosine component of theflange angle. The length L_(f1) of the flange raw material portion 58F1is a sum of the length l_(f1) of the flange 28 f 1 and twice the size ofthe excess margin e although not illustrated in FIG. 23. The platethickness T_(f1) of the flange raw material portion 58F1 is a lengthequal to or more than a product of a value obtained by subtracting aproduct of a half of the plate thickness T_(w) of the main plate rawmaterial portion 58W and cos θ1 corresponding to a cosine component ofthe flange angle from the height H_(f1) of the flange raw materialportion 58F1, and the parameter based on the substance. The flange 28 f1 is provided at the end part of the main plate portion 28 w, and thusthe plate thickness T_(f1) of the flange raw material portion 58F1secures the excess margin e on the end part side of the main plateportion 28 w.

The height H_(f2) of the flange raw material portion 58F2 is a sum ofthe height h_(f2) of the flange 28 f 2, and a product of the size of theexcess margin e and cos θ2 corresponding to a cosine component of theflange angle. The length L_(f2) of the flange raw material portion 58F2is a sum of the length l_(f2) of the flange 28 f 2 and twice the size ofthe excess margin e although not illustrated in FIG. 23. The platethickness T_(f2) of the flange raw material portion 58F2 is a lengthequal to or more than a product of a value obtained by subtracting aproduct of a half of the plate thickness T_(w) of the main plate rawmaterial portion 58W and cos θ2 corresponding to a cosine component ofthe flange angle from the height H_(f2) of the flange raw materialportion 58F2, and the parameter based on the substance. The flange 28 f2 is provided at the end part of the main plate portion 28 w, and thusthe plate thickness T_(f2) of the flange raw material portion 58F2secures the excess margin e on the end part side of the main plateportion 28 w.

The cross raw material portion 58M has a size and a shape causing thesize and the shape of the main plate raw material portion 58W, the sizeand the shape of the flange raw material portion 58F1, and the size andthe shape of the flange raw material portion 58F2 to be smoothlyconnected to each other.

Since the flange 28 f 1 protrudes in the height direction from one endpart of the main plate portion 28 w, the height H of the raw material 58is a value obtained by adding a height of the grip portion v and aheight of the cutting portion c to a sum of a flange position of theflange 28 f 1, a product of the height H_(w) of the main plate rawmaterial portion 58W and sin θ1 corresponding to a sine component of theflange angle, and a product of the plate thickness T_(f1) of the flangeraw material portion 58F1 and cos θ1 corresponding to a cosine componentof the flange angle. Although not illustrated in FIG. 23, the length Lof the raw material 58 is the largest length among the length L_(w) ofthe main plate raw material portion 58W, the length L_(f1) of the flangeraw material portion 58F1, and the length L_(f2) of the flange rawmaterial portion 58F2. Since the flange 28 f 1 and the flange 28 f 2 areprovided on both sides of the main plate portion 28 w in the directionof the plate thickness t_(w) of the main plate portion 28 w, the width Wof the raw material 58 is a sum of a product of the height H_(f1) of theflange raw material portion 58F1 and cos θ1 corresponding to a cosinecomponent of the flange angle, a product of the plate thickness T_(f1)of the flange raw material portion 58F1 and sin θ1 corresponding to asine component of the flange angle, a product of the height H_(f2) ofthe flange raw material portion 58F2 and cos θ2 corresponding to acosine component of the flange angle, and a product of the platethickness T_(f2) of the flange raw material portion 58F2 and sin θ2corresponding to a sine component of the flange angle.

FIG. 24 is a side view illustrating a raw material 62 which is anexample of a raw material determined according to the raw material shapedetermination method. The raw material 62 is calculated and determinedon the basis of the information regarding the shape of the material 32.The raw material 62 includes, as illustrated in FIG. 24, a main plateraw material portion 62W, a flange raw material portion 62F, and a crossraw material portion 62M. The main plate raw material portion 62W is aportion to be processed to the main plate portion 32 w. The flange rawmaterial portion 62F is a portion to be processed to the flange 32 f.The cross raw material portion 62M is a portion to be processed to thecross part 32 m.

The height H_(w) of the main plate raw material portion 62W is a sum ofthe height h_(w) of the main plate portion 32 w, a size of the excessmargin e, a height of the grip portion v, and a height of the cuttingportion c. Although not illustrated in FIG. 24, the length L_(w) of themain plate raw material portion 62W is a sum of the length l_(w) of themain plate portion 32 w and twice the size of the excess margin e. Theplate thickness T_(w) of the main plate raw material portion 62W is alength equal to or more than a product of a value obtained bysubtracting the height of the grip portion v from the height H_(w) ofthe main plate raw material portion 62W, and the parameter based on thesubstance.

The height H_(f) of the flange raw material portion 62F is a sum of theheight h_(f) of the flange 32 f and the size of the excess margin e. Thelength L_(f) of the flange raw material portion 62F is a sum of thelength l_(f) of the flange 32 f and twice the size of the excess margine although not illustrated in FIG. 24. The plate thickness T_(f) of theflange raw material portion 62F is a length equal to or more than aproduct of a value obtained by subtracting a half of the plate thicknessT_(w) of the main plate raw material portion 62W from the height H_(f)of the flange raw material portion 62F, and the parameter based on thesubstance.

The cross raw material portion 62M has a size and a shape causing thesize and the shape of the main plate raw material portion 62W to besmoothly connected to the size and the shape of the flange raw materialportion 62F.

Since the flange 32 f does not protrude in the height direction fromboth end parts of the main plate portion 32 w, the height H of the rawmaterial 62 is the same as the height H_(w) of the main plate rawmaterial portion 62W. Although not illustrated in FIG. 24, the length Lof the raw material 62 is a larger length of the length L_(w) of themain plate raw material portion 62W and the length L_(f) of the flangeraw material portion 62F. Since the flange 32 f is provided on only oneside of the main plate portion 32 w in the direction of the platethickness t_(w) of the main plate portion 32 w, the width W of the rawmaterial 62 is a sum of the height H_(f) of the flange raw materialportion 62F and a value of a half of the plate thickness T_(w) of themain plate raw material portion 62W.

FIG. 25 is a side view illustrating a raw material 64 which is anexample of a raw material determined according to the raw material shapedetermination method. The raw material 64 is calculated and determinedon the basis of the information regarding the shape of the material 34.The raw material 64 includes, as illustrated in FIG. 25, a main plateraw material portion 64W, a flange raw material portion 64F, and a crossraw material portion 64M. The main plate raw material portion 64W is aportion to be processed to the main plate portion 34 w. The flange rawmaterial portion 64F is a portion to be processed to the flange 34 f.The cross raw material portion 64M is a portion to be processed to thecross part 34 m.

The height H_(w) of the main plate raw material portion 64W is a sum ofthe height h_(w) of the main plate portion 34 w, a size of the excessmargin e, a height of the grip portion v, and a height of the cuttingportion c. Although not illustrated in FIG. 25, the length L_(w) of themain plate raw material portion 64W is a sum of the length l_(w) of themain plate portion 34 w and twice the size of the excess margin e. Theplate thickness T_(w) of the main plate raw material portion 64W is alength equal to or more than a product of a value obtained bysubtracting the height of the grip portion v from the height H_(w) ofthe main plate raw material portion 64W, and the parameter based on thesubstance.

The height H_(f) of the flange raw material portion 64F is a sum of theheight h_(f) of the flange 34 f, and a product of the size of the excessmargin e and cos θ corresponding to a cosine component of the flangeangle. The length L_(f) of the flange raw material portion 64F is a sumof the length l_(f) of the flange 34 f and twice the size of the excessmargin e although not illustrated in FIG. 25. The plate thickness T_(f)of the flange raw material portion 64F is a length equal to or more thana product of a value obtained by subtracting a product of a half of theplate thickness T_(w) of the main plate raw material portion 64W and cosθ corresponding to a cosine component of the flange angle from theheight H_(f) of the flange raw material portion 64F, and the parameterbased on the substance.

The cross raw material portion 64M has a size and a shape causing thesize and the shape of the main plate raw material portion 64W to besmoothly connected to the size and the shape of the flange raw materialportion 64F.

The height H of the raw material 64 differs depending on whether or notthe flange 34 f protrudes in the height direction from both end parts ofthe main plate portion 34 w. Specifically, in a case where the flange 34f does not protrude from both end parts of the main plate portion 34 w,the height H of the raw material 64 is the same as the height H_(w) ofthe main plate raw material portion 64W. On the other hand, in a casewhere the flange 34 f protrudes in the height direction from one endpart of the main plate portion 34 w, the height H of the raw material 64is a value obtained by adding a height of the grip portion v and aheight of the cutting portion c to a sum of a flange position, a productof the height H_(w) of the main plate raw material portion 64W and sin θcorresponding to a sine component of the flange angle, and a product ofthe plate thickness T_(f) of the flange raw material portion 64F and cosθ corresponding to a cosine component of the flange angle.

Although not illustrated in FIG. 25, the length L of the raw material 64is a larger length of the length L_(w) of the main plate raw materialportion 64W and the length L_(f) of the flange raw material portion 64F.Since the flange 34 f is provided on only one side of the main plateportion 34 w in the direction of the plate thickness t_(w) of the mainplate portion 34 w, the width W of the raw material 64 is a sum of aproduct of the height H_(f) of the flange raw material portion 64F andcos θ corresponding to a cosine component of the flange angle, a productof the plate thickness T_(f) of the flange raw material portion 64F andsin θ corresponding to a sine component of the flange angle, and a valueof a half of the plate thickness T_(w) of the main plate raw materialportion 64W.

FIG. 26 is a side view illustrating a raw material 66 which is anexample of a raw material determined according to the raw material shapedetermination method. The raw material 66 is calculated and determinedon the basis of the information regarding the shape of the material 36.The raw material 66 includes, as illustrated in FIG. 26, a main plateraw material portion 66W, a flange raw material portion 66F1, a flangeraw material portion 66F2, and a cross raw material portion 66M. Themain plate raw material portion 66W is a portion to be processed to themain plate portion 36 w. The flange raw material portion 66F1 is aportion to be processed to the flange 36 f 1. The flange raw materialportion 66F2 is a portion to be processed to the flange 36 f 2. Thecross raw material portion 66M is a portion to be processed to the crosspart 36 m.

The height H_(w) of the main plate raw material portion 66W is a sum ofthe height h_(w) of the main plate portion 36 w, a size of the excessmargin e, a height of the grip portion v, and a height of the cuttingportion c. Although not illustrated in FIG. 26, the length L_(w) of themain plate raw material portion 66W is a sum of the length l_(w) of themain plate portion 36 w and twice the size of the excess margin e. Theplate thickness T_(w) of the main plate raw material portion 66W is alength equal to or more than a product of a value obtained bysubtracting the height of the grip portion v from the height H_(w) ofthe main plate raw material portion 66W, and the parameter based on thesubstance.

The height H_(f1) of the flange raw material portion 66F1 is a sum ofthe height h_(f1) of the flange 36 f 1 and the size of the excess margine. The length L_(f1) of the flange raw material portion 66F1 is a sum ofthe length l_(f1) of the flange 36 f 1 and twice the size of the excessmargin e although not illustrated in FIG. 26. The plate thickness T_(f1)of the flange raw material portion 66F1 is a length equal to or morethan a product of a value obtained by subtracting a half of the platethickness T_(w) of the main plate raw material portion 66W from theheight H_(f1) of the flange raw material portion 66F1, and the parameterbased on the substance.

The height H_(f2) of the flange raw material portion 66F2 is a sum ofthe height h_(f2) of the flange 36 f 2 and the size of the excess margine. The length L_(f2) of the flange raw material portion 66F2 is a sum ofthe length l_(f2) of the flange 36 f 2 and twice the size of the excessmargin e although not illustrated in FIG. 26. The plate thickness T_(f2)of the flange raw material portion 66F2 is a length equal to or morethan a product of a value obtained by subtracting a half of the platethickness T_(w) of the main plate raw material portion 66W from theheight H_(f2) of the flange raw material portion 66F2, and the parameterbased on the substance.

The cross raw material portion 66M has a size and a shape causing thesize and the shape of the main plate raw material portion 66W, the sizeand the shape of the flange raw material portion 66F1, and the size andthe shape of the flange raw material portion 66F2 to be smoothlyconnected to each other.

Since the flange 36 f 1 and the flange 36 f 2 do not protrude in theheight direction from both end parts of the main plate portion 36 w, theheight H of the raw material 66 is the same as the height H_(w) of themain plate raw material portion 66W. Although not illustrated in FIG.26, the length L of the raw material 66 is the largest length among thelength L_(w) of the main plate raw material portion 66W, the lengthL_(f1) of the flange raw material portion 66F1, and the length L_(f2) ofthe flange raw material portion 66F2. Since the flange 36 f 1 and theflange 36 f 2 are provided on both sides of the main plate portion 36 win the direction of the plate thickness t_(w) of the main plate portion36 w, the width W of the raw material 66 is a sum of the height H_(f1)of the flange raw material portion 66F1 and height H_(f2) of the flangeraw material portion 66F2.

FIG. 27 is a side view illustrating a raw material 68 which is anexample of a raw material determined according to the raw material shapedetermination method. The raw material 68 is calculated and determinedon the basis of the information regarding the shape of the material 38.The raw material 68 includes, as illustrated in FIG. 27, a main plateraw material portion 68W, a flange raw material portion 68F1, a flangeraw material portion 68F2, and a cross raw material portion 68M. Themain plate raw material portion 68W is a portion to be processed to themain plate portion 38 w. The flange raw material portion 68F1 is aportion to be processed to the flange 38 f 1. The flange raw materialportion 68F2 is a portion to be processed to the flange 38 f 2. Thecross raw material portion 68M is a portion to be processed to the crosspart 38 m.

The height H_(w) of the main plate raw material portion 68W is a sum ofthe height h_(w) of the main plate portion 38 w, a size of the excessmargin e, a height of the grip portion v, and a height of the cuttingportion c. Although not illustrated in FIG. 27, the length L_(w) of themain plate raw material portion 68W is a sum of the length l_(w) of themain plate portion 38 w and twice the size of the excess margin e. Theplate thickness T_(w) of the main plate raw material portion 68W is alength equal to or more than a product of a value obtained bysubtracting the height of the grip portion v from the height H_(w) ofthe main plate raw material portion 68W, and the parameter based on thesubstance.

The height H_(f1) of the flange raw material portion 68F1 is a sum ofthe height h_(f1) of the flange 38 f 1, and a product of the size of theexcess margin e and cos θ1 corresponding to a cosine component of theflange angle. The length L_(f1) of the flange raw material portion 68F1is a sum of the length l_(f1) of the flange 38 f 1 and twice the size ofthe excess margin e although not illustrated in FIG. 27. The platethickness T_(f1) of the flange raw material portion 68F1 is a lengthequal to or more than a product of a value obtained by subtracting aproduct of a half of the plate thickness T_(w) of the main plate rawmaterial portion 68W and cos θ1 corresponding to a cosine component ofthe flange angle from the height H_(f1) of the flange raw materialportion 68F1, and the parameter based on the substance.

The height H_(f2) of the flange raw material portion 68F2 is a sum ofthe height h_(f2) of the flange 38 f 2, and a product of the size of theexcess margin e and cos θ2 corresponding to a cosine component of theflange angle. The length L_(f2) of the flange raw material portion 68F2is a sum of the length l_(f2) of the flange 38 f 2 and twice the size ofthe excess margin e although not illustrated in FIG. 27. The platethickness T_(f2) of the flange raw material portion 68F2 is a lengthequal to or more than a product of a value obtained by subtracting aproduct of a half of the plate thickness T_(w) of the main plate rawmaterial portion 68W and cos θ2 corresponding to a cosine component ofthe flange angle from the height H_(f2) of the flange raw materialportion 68F2, and the parameter based on the substance.

The cross raw material portion 68M has a size and a shape causing thesize and the shape of the main plate raw material portion 68W, the sizeand the shape of the flange raw material portion 68F1, and the size andthe shape of the flange raw material portion 68F2 to be smoothlyconnected to each other.

The height H of the raw material 68 differs depending on whether or notthe flange 38 f 1 and the flange 38 f 2 protrude in the height directionfrom both end parts of the main plate portion 38 w. Specifically, in acase where the flange 38 f 1 and the flange 38 f 2 do not protrude fromboth end parts of the main plate portion 38 w, the height H of the rawmaterial 68 is the same as the height H_(w) of the main plate rawmaterial portion 68W. On the other hand, in a case where in a case wherethe flange 38 f 1 and the flange 38 f 2 protrude from one end part ofthe main plate portion 38 w, for example, as illustrated in FIG. 27, theflange 38 f 1 protrudes in the height direction from one end part of themain plate portion 38 w, the height H of the raw material 68 is a valueobtained by adding a height of the grip portion v and a height of thecutting portion c to a sum of a flange position of the flange 38 f 1, aproduct of the height H_(w) of the main plate raw material portion 68Wand sin θ1 corresponding to a sine component of the flange angle, and aproduct of the plate thickness T_(f1) of the flange raw material portion68F1 and cos θ1 corresponding to a cosine component of the flange angle.

Although not illustrated in FIG. 27, the length L of the raw material 68is the largest length among the length L_(w) of the main plate rawmaterial portion 68W, the length L_(f1) of the flange raw materialportion 68F1, and the length L_(f2) of the flange raw material portion68F2. Since the flange 38 f 1 and the flange 38 f 2 are provided on bothsides of the main plate portion 38 w in the direction of the platethickness t_(w) of the main plate portion 38 w, the width W of the rawmaterial 68 is a sum of a product of the height H_(f1) of the flange rawmaterial portion 68F1 and cos θ1 corresponding to a cosine component ofthe flange angle, a product of the plate thickness T_(f1) of the flangeraw material portion 68F1 and sin θ1 corresponding to a sine componentof the flange angle, a product of the height H_(f2) of the flange rawmaterial portion 68F2 and cos θ2 corresponding to a cosine component ofthe flange angle, and a product of the plate thickness T_(f2) of theflange raw material portion 68F2 and sin θ2 corresponding to a sinecomponent of the flange angle.

Hereinafter, a description will be made of operations of the numericalcontrol program generation system 12 and the numerical control programgeneration program 16. FIG. 28 is a flowchart illustrating an example ofa flow of a numerical control program generation method. The numericalcontrol program generation method is a processing method performed bythe control section 12 c reading and executing the numerical controlprogram generation program 16 in the numerical control programgeneration system 12. The numerical control program generation methodwill be described with reference to FIG. 28. The numerical controlprogram generation method includes, as illustrated in FIG. 28, elementcreation step S62, element reading step S64, tool path generation stepS66, tool path connection step S67, and numerical control programverification step S69. Hereinafter, element creation step S62, elementreading step S64, tool path generation step S66, tool path connectionstep S67, and numerical control program verification step S69 will berespectively simply referred to as step S62, step S64, step S66, stepS67, and step S69, as appropriate.

First, the control section 12 c creates elements regarding a shape of amaterial on the basis of information regarding the shape of the material(step S62). The elements regarding the shape of the material include acutting condition setting element which is an element for setting acutting condition and a tool path generation element which is an elementfor generating a tool path. Elements are created for each surfaceelement included in the shape of the material.

Element creation step S62 will be described below in detail. FIG. 29 isa flowchart illustrating an example of a detailed flow of elementcreation step S62. Element creation step S62 includes, as illustrated inFIG. 29, material shape acquisition step S71, material shapeidentification step S72, material element identification step S73, rawmaterial shape acquisition step S74, raw material element identificationstep S75, cutting condition setting element extraction step S77, toolpath generation element creation step S78, and tool path elementclassification step S79. Hereinafter, material shape acquisition stepS71, material shape identification step S72, material elementidentification step S73, raw material shape acquisition step S74, rawmaterial element identification step S75, cutting condition settingelement extraction step S77, tool path generation element creation stepS78, and tool path element classification step S79 will be respectivelysimply referred to as step S71, step S72, step S73, step S74, step S75,step S77, step S78, and step S79, as appropriate.

FIG. 30 is a perspective view illustrating a material design model 70which is an example of a material shape. The material design model 70 isa three-dimensional design model created for a material. In elementcreation step S62, first, the control section 12 c acquires informationregarding a shape of a material in the same manner as in the above stepS12 (step S71). Specifically, the control section 12 c acquires data ofa three-dimensional design model created for the material, for example,the material design model 70 illustrated in FIG. 30, by executing thecomputer aided design program 17. Hereinafter, as an embodiment, adescription will be made of an example of handling the material designmodel 70.

FIG. 31 is a diagram illustrating identification conditions 72 which areexamples of identification conditions for the material design model 70.After step S71, the control section 12 c identifies the shape of thematerial on the basis of the information regarding the shape of thematerial acquired in step S71 (step S72). Specifically, the controlsection 12 c identifies the material design model 70 according to theidentification conditions 72 illustrated in FIG. 31.

FIG. 32 is a sectional view illustrating a flange angle RA which is anexample of a flange angle of 90 degrees. FIG. 33 is a sectional viewillustrating a flange angle AA which is an example of a flange angle ofan acute angle. FIG. 34 is a perspective view illustrating a flange stepportion FS which is an example of a step portion in a flange. FIG. 35 isa perspective view illustrating a mouse hole MH which is an example of amouse hole. The identification conditions 72 include the type of flange,a size of a material, a flange angle, the presence or absence of a stepportion in a flange, and the presence or absence of a mouse hole. Thetype of flange includes, for example, four kinds such as an L typeflange, a T type flange, a counterclockwise-T type flange, and a “+”type flange classified in the above step S14. The size of a materialincludes, for example, about three kinds. The flange angle includes, forexample, two kinds such as the flange angle RA illustrated in FIG. 32 inwhich a flange angle is 90 degrees and the flange angle AA illustratedin FIG. 33 in which a flange angle is an acute angle or an obtuse angle.The presence or absence of a step portion in a flange includes, forexample, two kinds such as a case where the flange step portion FShaving a predetermined size, for example, a size equal to or less thanR10 illustrated in FIG. 34, and a case where the flange step portion FSis not provided. The presence or absence of a step portion in a flangemay be regarded as the presence or absence of a plate thickness change.The presence or absence of a mouse hole includes, for example, two kindssuch as a case where the mouse hole MH illustrated in FIG. 35 isprovided and a case where the mouse hole MH is not provided. In thiscase, the identification conditions 72 include a total of 96 kinds ofidentification conditions. Specifically, in step S72, the controlsection 12 c identifies the material design model 70 illustrated in FIG.30 as the kind that the flange type is a T type flange, a material sizeis medium, a flange angle is 90 degrees, a flange step portion isabsent, and a mouse hole is absent.

After step S72, the control section 12 c identifies an element of thematerial design model 70 (step S73). FIG. 36 is a perspective viewillustrating a similar material design model 74 which is an example ofan existing material design model and of which a shape is closest to amaterial shape, that is, which is of the same kind as the materialdesign model 70. In step S73, in the present embodiment, the controlsection 12 c identifies an element of the material design model 70through comparison with an element of the similar material design model74 and by correlating associated portions of the material design model70 and the similar material design model 74 with each other so as to seta correlation. Step S73 is not limited thereto, and other methods may beused, such as a method not using the similar material design model 74.

Hereinafter, material element identification step S73 processed by usingthe similar material design model 74 will be described in detail. FIG.37 is a flowchart illustrating an example of a detailed flow of materialelement identification step S73. Material element identification stepS73 includes, as illustrated in FIG. 37, automatic identificationpossibility determination step S81, automatic identification step S82,model element name possibility determination step S84, model elementname identification step S85, and semi-automatic identification stepS87. Hereinafter, automatic identification possibility determinationstep S81, automatic identification step S82, model element namepossibility determination step S84, model element name identificationstep S85, and semi-automatic identification step S87 will berespectively simply referred to as step S81, step S82, step S84, stepS85, and step S87 as appropriate.

In material element identification step S73, first, the control section12 c performs a partial process of automatic identification step S82 onthe material design model 70 and the similar material design model 74,so as to determine whether or not an element of the material designmodel 70 can be automatically identified (step S81). In a case where itis determined that an element of the material design model 70 can beautomatically identified (Yes in step S81), the control section 12 cperforms a remaining process of automatic identification step S82 on thematerial design model 70 so as to automatically identify the element ofthe material design model 70 (step S82). On the other hand, in a casewhere it is determined that an element of the material design model 70cannot be automatically identified (No in step S81), the control section12 c stops the process of automatic identification step S82 on thematerial design model 70, and causes the process to proceed to step S84.

Automatic identification step S82 will be described below in detail.FIG. 38 is a flowchart illustrating an example of a detailed flow in acase where an element of the material design model 70 is automaticallyidentified. Automatic identification step S82 includes, as illustratedin FIG. 38, surface element extraction step S91, first reference surfacesetting step S92, second reference surface setting step S93, coordinateaxis creation step S94, surface edge line automatic detection step S96,and automatic comparison detection step S98. Hereinafter, surfaceelement extraction step S91, first reference surface setting step S92,second reference surface setting step S93, coordinate axis creation stepS94, surface edge line automatic detection step S96, and automaticcomparison detection step S98 will be respectively simply referred to asstep S91, step S92, step S93, step S94, step S96, and step S98 asappropriate.

In automatic identification step S82, first, the control section 12 cextracts all surface elements of the material design model 70 and thesimilar material design model 74 (step S91). In step S91, a referenceregarding whether or not a plurality of surface elements are regarded asa single surface element is, for example, the curved portion 41, thetapered portion 42, the step portion 43, and the step portion 44, orwhether or not a change in a height in a direction perpendicular to asurface is equal to or less than a predetermined threshold value.

After the process of step S91, among the all of extracted surfaceelements, the control section 12 c sets a surface element including astraight line corresponding to the longest distance between two pointsas a first reference surface in each of the material design model 70 andthe similar material design model 74 (step S92). For example, thecontrol section 12 c sets a surface element satisfying theabove-described conditions as a first reference surface 76 in thesimilar material design model 74 as illustrated in FIG. 36.

After the process of step S92, among surface elements orthogonal to thefirst reference surface set in step S92, the control section 12 c sets asurface element including a straight line corresponding to the longestdistance between two points as a second reference surface in each of thematerial design model 70 and the similar material design model 74 (stepS93). For example, the control section 12 c sets a surface elementsatisfying the above-described conditions as a second reference surface77 in the similar material design model 74 as illustrated in FIG. 36.

After the process of step S93, the control section 12 c createscoordinate axes having an intersection line between the first referencesurface set in step S92 and the second reference surface set in step S93as an X axis and any one straight line orthogonal to the first referencesurface as a Z axis in each of the material design model 70 and thesimilar material design model 74 (step S94). For example, as illustratedin FIG. 36, in the similar material design model 74, the control section12 c creates coordinate axes 78 having an intersection line between thefirst reference surface 76 and the second reference surface 77 as an Xaxis and any one straight line orthogonal to the first reference surface76 as a Z axis in the similar material design model 74, as illustratedin FIG. 36.

After the process of step S94, the control section 12 c automaticallydetects an edge line which is a boundary between surface elements ineach of the material design model 70 and the similar material designmodel 74 (step S96). In this case, the control section 12 c also detectsinformation regarding the surface elements and the edge line.

After the process of step S96, the control section 12 c compares thematerial design model 70 with the similar material design model 74, anddetects and sets correlations between the surface elements and the edgeline of the material design model 70 and the surface elements and theedge line of the similar material design model 74 automatically detectedin step S96 (step S98). In this case, the control section 12 c detectsthe correlations by regarding that portions having close coordinateinformation are corresponding portions on the basis of the coordinateaxes of each of the material design model 70 and the similar materialdesign model 74.

In a case where the processes of step S91 to step S98 can be smoothlyperformed, and correlations can be set between the material design model70 and the similar material design model 74, the control section 12 cdetermines that an element of the material design model 70 can beautomatically identified (Yes in step S81), and can thus identify anelement of the material design model 70 which is an identificationtarget for each surface element (step S82).

In a case where the processes of step S91 to step S98 cannot be smoothlyperformed, the control section 12 c determines that an element of thematerial design model 70 cannot be automatically identified (No in stepS81), stops the process of automatic identification step S82 on thematerial design model 70, and causes the process to proceed to step S84.

FIG. 39 is a diagram illustrating an example of an automaticidentification state in a case where automatic identification isperformed on the basis of a model element name. In a case where theprocess proceeds to step S84, the control section 12 c determineswhether or not an element of the material design model 70 can beautomatically identified on the basis of model element names 79illustrated in FIG. 39 in the material design model 70 (step S84). In acase where the model element name 79 used in the material design model70 matches a model element name used in the similar material designmodel 74, for example, the model element name 79 such as a referencecoordinate axis, a reference surface A, a reference element A, or areference element B illustrated in FIG. 39 is used in common to thematerial design model 70 and the similar material design model 74, thecontrol section 12 c determines that an element of the material designmodel 70 can be automatically identified on the basis of the modelelement name 79 in the material design model 70 (Yes in step S84). In acase where it is determined that an element of the material design model70 can be automatically identified on the basis of the model elementname 79 in the material design model 70 (Yes in step S84), the controlsection 12 c sets a correlation between the model element name 79 in thematerial design model 70 and a model element name in the similarmaterial design model 74, so as to detect and set correlations betweenthe surface elements and the edge line of the material design model 70and the surface elements and the edge line of the similar materialdesign model 74 (step S85).

In a case where an element of the material design model 70 cannot beautomatically identified, and the model element name 79 used in thematerial design model 70 does not match a model element name used in thesimilar material design model 74, the control section 12 c determinesthat an element of the material design model 70 can be automaticallyidentified on the basis of the model element name 79 in the materialdesign model 70 (No in step S84), and causes the process to proceed tostep S87.

FIG. 40 is a diagram illustrating an example of a reference elementselection state in a case where semi-automatic identification isperformed on the basis of reference element selection. In a case wherethe process proceeds to step S87, the control section 12 c temporarilystops the process of automatically identifying an element of thematerial design model 70, and receives input of correlations between thematerial design model 70 and the similar material design model 74. Asillustrated in FIG. 40, in a case where surface elements and an edgeline of the material design model 70 are selected on a right window inFIG. 40 with, for example, a mouse, surface elements and an edge line ofthe similar material design model 74 are selected on the whole windowincluding the right window in FIG. 40, and some correlationstherebetween are input, the control section 12 c can automaticallydetect remaining correlations between the material design model 70 andthe similar material design model 74 by using mutual coordinate axes andpositional relationships on the basis of the input correlations.Consequently, the control section 12 c detects and sets correlationsbetween the surface elements and the edge line of the material designmodel 70 and the surface elements and the edge line of the similarmaterial design model 74 (step S87).

The control section 12 c detects and sets correlations between thesurface elements and the edge line of the material design model 70 andthe surface elements and the edge line of the similar material designmodel 74 in automatic identification step S82, model element nameidentification step S85, and semi-automatic identification step S87. Inother words, the control section 12 c matches the material design model70 with the similar material design model 74 in automatic identificationstep S82, model element name identification step S85, and semi-automaticidentification step S87. Specifically, the control section 12 cgenerates information in which the surface elements and the edge line ofthe material design model 70 and the surface elements and the edge lineof the similar material design model 74 are correlated with each other,that is, material correlation information, and information regardingsimilarities and differences between correlated portions. The controlsection 12 c performs a division process on an element on the basis ofthe correlation information and the information regarding similaritiesand differences between correlated portions. Consequently, the controlsection 12 c finishes the process of material element identificationstep S73, and causes the process to proceed to raw material shapeacquisition step S74.

Referring to FIG. 29 again, the control section 12 c acquiresinformation regarding the shape of the raw material calculated anddetermined in the raw material shape determination system 11 on thebasis of the shape of the material which is a target (step S74). FIG. 41is a diagram illustrating a raw material design model 80 which is anexample of a raw material design model. Specifically, in step S74, thecontrol section 12 c acquires the raw material design model 80 asillustrated in FIG. 41, including the information regarding the shape ofthe raw material which is a target, from the raw material shapedetermination system 11. Consequently, the control section 12 c is in astate of acquiring the information regarding the shape of the rawmaterial corresponding to a shape at a processing start point as the rawmaterial design model 80, and acquiring the information regarding theshape of the material corresponding to a shape at a processing end pointas the material design model 70.

After the process of step S74, the control section 12 c identifies anelement of the raw material design model 80 on the basis of the materialcorrelation information, and the information regarding similarities anddifferences between correlated portions generated in step S73 andinformation regarding the raw material design model 80 acquired in stepS74 (step S75). Specifically, first, the control section 12 c setscorrelations between elements of the raw material design model 80 andthe surface elements and the edge line of the material design model 70by using information regarding a correlation of each element between thematerial and the raw material included in the raw material design model80. Next, the control section 12 c sets correlations between the surfaceelements and the edge line of the raw material design model 80 and thesurface elements and the edge line of the similar material design model74 by using the material correlation information, and the informationregarding similarities and differences between correlated portions, andidentifies an element of the raw material design model 80 for each kindof cutting condition on the basis of information regarding cuttingconditions preset for the surface elements and the edge line of thesimilar material design model 74.

FIG. 42 is a diagram illustrating an element division method 82 which isan example of an element division method in the raw material designmodel. For example, through the process of step S75, as illustrated inFIGS. 41 and 42, the raw material design model 80 is identified into aflange end part processing element E1, a flange surface processingelement E2, a cross part processing element E3, a main plate portion endpart processing element E4, a main plate portion surface processingelement E5, a cutting portion processing element E6, and several boringelements. A tool path generation element is created for all of theprocessing elements, and thus “O” is added to tool path fields of all ofthe processing elements in the element division method illustrated inFIG. 42. Since the flange surface processing element E2, the cross partprocessing element E3, and the main plate portion surface processingelement E5 are influenced by the rigidity of a raw material or amaterial during processing, and thus a cutting condition setting elementis required to be created, cutting condition setting fields in suchprocessing elements are added with “O” in the element division method82. On the other hand, since the flange end part processing element E1,the main plate portion end part processing element E4, the cuttingportion processing element E6, and several boring elements are notinfluenced by the rigidity of a raw material or a material duringprocessing, and thus a cutting condition setting element is not requiredto be created, cutting condition setting fields in such processingelements are added with “−” in the element division method 82.

Referring to FIG. 29 again, after the process of step S75, the controlsection 12 c extracts a cutting condition setting element for processingthe material shown in the material design model 70 from the raw materialshown in the raw material design model 80 (step S77). In step S77,specifically, the control section 12 c extracts various values requiredto easily calculate static rigidity of the raw material or the materialduring processing in order to set cutting conditions. FIG. 43 is adiagram illustrating examples of cutting condition setting elements.Cutting condition setting elements extracted by the control section 12 cin step S77 include, for example, not only the height h_(w) and theplate thickness t_(w) of the main plate portion in the material designmodel 70 illustrated in FIG. 43 and the height h_(f) and the platethickness t_(f) of the flange in the material design model 70illustrated in FIG. 43, but also the length l_(w) of the main plateportion and the length l_(f) of the flange in the material design model70, the height H_(w) and the plate thickness T_(w) of the main plate rawmaterial portion in the raw material design model 80, the height H_(f)and the plate thickness T_(f) of the flange raw material portion in theraw material design model 80, the length L_(w) of the main plate rawmaterial portion and the length L_(f) of the flange raw material portionin the raw material design model 80, Young's moduli E of substances ofthe raw material and the material, and parameters based on substancespredefined according to rigidities of the substances of the raw materialand the material.

Referring to FIG. 29 again, after the process of step S77, the controlsection 12 c creates a tool path generation element for processing thematerial shown in the material design model 70 on the basis of the rawmaterial shown in the raw material design model 80 (step S78). In theprocess of step S78, the control section 12 c creates a tool pathgeneration element which is an element for generating a tool path inwhich a route of a processing operation is coded for each elementidentified in step S75. Specifically, the control section 12 c sets asurface element, an end part element, and a cross part element where twoor more surface elements cross each other, and sets some surfaceelements and cross part elements influenced by the rigidity of the rawmaterial or the material, as elements for generating a tool path byusing the cutting condition setting elements. FIG. 44 is a diagramillustrating examples of tool path generation elements. For example,tool path generation elements created in step S78 include, asillustrated in FIG. 44, a flange outer periphery finishing element EL1,a flange surface processing element EL2, a flange boring element EL3, alength direction end part processing element EL4, a main plate portionsurface processing element EL5, a main plate portion boring element EL6,and a cutting element EL7.

Each element includes information regarding a processing order andinformation regarding setting of cutting conditions. Specifically, sincethe flange outer periphery finishing element EL1 is a surface elementorthogonal to the height direction of the flange at a location farthestfrom the grip portion v, the flange outer periphery finishing elementEL1 is set next to the length direction end part processing element EL4corresponding to processing of end surfaces at both ends in the axialdirection in a processing order, is not related to processing on asurface element or a cross part, and is thus set as an element forgenerating a tool path in which processing is performed once withoutusing a cutting condition setting element. Since the flange surfaceprocessing element EL2 is a surface element along the axial directionand the height direction of the flange at a location farthest from thegrip portion v, the flange surface processing element EL2 is set next tothe flange outer periphery finishing element EL1 in a processing order,is related to processing on a surface element or a cross part, and isthus set as an element for generating a tool path in which processing isdivided into roughing and finishing and is performed a plurality oftimes by using a cutting condition setting element. Since the flangeboring element EL3 is a boring element, the flange boring element EL3 isset after predetermined roughing in the flange surface processingelement EL2 and before predetermined finishing in the flange surfaceprocessing element EL2 in a processing order, and is set as an elementfor generating a tool path in which processing is performed on the basisof a predetermined boring method without using a cutting conditionsetting element.

The roughing is processing in which a rotation speed of a tool is high,a processing margin which is a depth processed by the tool is large, anda processing pitch which is a region processed by the tool is large, andis processing in which a processing speed is prioritized to the accuracyof processing and a reduction of the influence exerted on the rawmaterial and the material during processing. The roughing is processingfor making the raw material close to the shape of the material, forexample, cutting. On the other hand, the finishing is processing inwhich a rotation speed of a tool is lower than in the roughing, aprocessing margin which is a depth processed by the tool is small, and aprocessing pitch which is a region processed by the tool is small, andis processing in which the accuracy of processing and a reduction of theinfluence exerted on the raw material and the material during processingare prioritized to a processing speed. The finishing is processing forfinishing the raw material to the shape of the material, for example,cutting. Thus, the roughing is appropriate for processing of endsurfaces at both ends in the axial direction and processing of a surfaceelement orthogonal to the height direction since the accuracy ofprocessing is not required to be taken into great consideration, and theinfluence exerted on the raw material and the material during processingis not required to be taken into consideration. On the other hand, thefinishing is appropriate for processing of a surface element along theaxial direction and the height direction since the accuracy ofprocessing is required to be taken into great consideration, and theinfluence exerted on the raw material and the material during processingis required to be taken into consideration. Thus, the roughing ispreferably used for processing of a surface element along the axialdirection and the height direction up to a stage in which the influenceexerted on the raw material and the material during processing may notbe taken into consideration, and the finishing is used in the subsequentstage.

Since the length direction end part processing element EL4 is related toprocessing of end surfaces at both ends in the axial direction, thelength direction end part processing element EL4 is set first in aprocessing order, is not related to processing on a surface element or across part, and is thus set as an element for generating a tool path inwhich processing is performed once without using a cutting conditionsetting element. Since the main plate portion surface processing elementEL5 is a surface element along the axial direction and the heightdirection of the flange at a location close to the grip portion v, themain plate portion surface processing element EL5 is set after flangeouter periphery finishing element EL1, the flange surface processingelement EL2, and the flange boring element EL3 in a processing order, isrelated to processing on a surface element or a cross part, and is thusset as an element for generating a tool path in which processing isdivided into roughing and finishing and is performed a plurality oftimes by using a cutting condition setting element. Since the main plateportion boring element EL6 is a boring element, the main plate portionboring element EL6 is set after predetermined roughing in main plateportion surface processing element EL5 and before predeterminedfinishing in main plate portion surface processing element EL5 in aprocessing order, and is set as an element for generating a tool path inwhich processing is performed on the basis of a boring method withoutusing a cutting condition setting element.

The cutting element EL7 is related to processing of separating thematerial from the grip portion v at the cutting portion c, and is thusset last in a processing order, and is set as an element for generatinga tool path in which the cutting element EL7 is processed to a pluralityof tab shapes corresponding to a cutout shape so as to be easilyseparated.

Referring to FIG. 29 again, after the process of step S78, the controlsection 12 c classifies the tool path generation elements created instep S78 (step S79). Specifically, the control section 12 c sortsprocessing layers for each tool path generation element created in stepS78. For example, the control section 12 c sorts layers so as to sortcolors to be displayed on a display for each tool path generationelement created in step S78. Consequently, the control section 12 cfinishes the process of element creation step S62 illustrated in FIG.28, and causes the process to proceed to element reading step S64.

Referring to FIG. 28 again, the control section 12 c performs a processof reading elements regarding the shape of the material created in stepS62, that is, elements including the cutting condition setting elementsand the tool path generation elements, generated for each surfaceelement included in the shape of the material, from a region in whichthe computer aided design program 17 is executed to a region in whichthe computer aided manufacturing program 18 is executed (step S64).Processes in the control section 12 c after step S64 are performed byexecuting the computer aided manufacturing program 18.

After step S64, the control section 12 c generates a tool path for eachelement read in step S64 (step S66). In a case where a tool path isgenerated for an element for generating the tool path without using acutting condition setting element, for example, in a case where a toolpath is generated for each of the flange outer periphery finishingelement EL1, the flange boring element EL3, the length direction endpart processing element EL4, the main plate portion boring element EL6,and the cutting element EL7 in the above example, the control section 12c selects tools used for machining on the basis of tool path generationelements set for the elements, and generates the tool path by selectingvalues of a database of the tools, or a tool path generated by usingpredetermined cutting conditions defined in the computer aidedmanufacturing program 18.

Even in a case where a tool path is generated by using a cuttingcondition setting element, the control section 12 c may use a tool pathwhich has been generated by using the similar material design model 74,with respect to a completely matching element between the materialdesign model 70 and the similar material design model 74. In a casewhere a tool path is generated by using a cutting condition settingelement, the control section 12 c preferably generates a tool path whichis changed according to a difference for a tool path which has beengenerated on the basis of the similar material design model 74 withrespect to elements having a similarity and a difference between thematerial design model 70 and the similar material design model 74. Thus,in the present embodiment, the control section 12 c performs a processof each step by using, as a reference, a tool path which has beengenerated on the basis of the similar material design model 74, in toolpath generation step S66 in a case where a tool path is generated byusing a cutting condition setting element.

Hereinafter, a description will be made of details of tool pathgeneration step S66 in a case where a tool path is generated by using acutting condition setting element, for example, a tool path for each ofthe flange surface processing element EL2 and the main plate portionsurface processing element EL5 in the above example is created. FIG. 45is a flowchart illustrating an example of a detailed flow of tool pathgeneration step S66 in this case. Tool path generation step S66includes, as illustrated in FIG. 45, tool path generation regionselection step S101, tool selection step S102, tool rotation speed/feedamount temporary setting step S104, cutting-amount-during-processingtemporary step S105, cutting-amount-within-tool-specificationdetermination step S107, temporarily-set-cutting-amount correction stepS108, processing region shape calculation step S111, processing regionstatic rigidity calculation step S112, tool cutting force calculationstep S113, tilt amount calculation step S114,tilt-amount-within-threshold-value determination step S116,temporarily-set-feed amount/cutting amount correction step S117, powerratio calculation step S121, power-ratio-within-threshold-valuedetermination step S122, tool temporary setting change step S123,selected region tool path generation step S125, and all-regions toolpath generation determination step S126. Hereinafter, tool pathgeneration region selection step S101, tool selection step S102, toolrotation speed/feed amount temporary setting step S104,cutting-amount-during-processing temporary step S105,cutting-amount-within-tool-specification determination step S107,temporarily-set-cutting-amount correction step S108, processing regionshape calculation step S111, processing region static rigiditycalculation step S112, tool cutting force calculation step S113, tiltamount calculation step S114, tilt-amount-within-threshold-valuedetermination step S116, temporarily-set-feed amount/cutting amountcorrection step S117, power ratio calculation step S121,power-ratio-within-threshold-value determination step S122, tooltemporary setting change step S123, selected region tool path generationstep S125, and all-regions tool path generation determination step S126will be respectively simply referred to as step S101, step S102, stepS104, step S105, step S107, step S108, step S111, step S112, step S113,step S114, step S116, step S117, step S121, step S122, step S123, stepS125, and step S126, as appropriate.

In tool path generation step S66 in a case where a tool path isgenerated by using a cutting condition setting element, first, thecontrol section 12 c selects a region for generating a tool path (stepS101). Specifically, the control section 12 c selects elements for whichtool paths are generated by using a cutting condition setting element,from a first element one by one among from the elements read in stepS64.

Next, the control section 12 c selects a tool used for machining on thebasis of the shape and the substance of the material design model 70 orthe raw material design model 80 included in the cutting conditionsetting element (step S102). Specifically, the control section 12 cselects a tool suitable for a combination of the shape and the substanceof the material design model 70 or the raw material design model 80 byusing a database of combinations of the shape and the substance of thematerial design model 70 or the raw material design model 80 and toolssuitable therefor. In step S102, an identical tool is preferablyselected to be used for roughing and finishing performed on an identicalelement. In step S102, an identical tool is preferably selected to beused for all elements. In step S102, in a case where an identical toolis selected to be used, a tool is not changed for a selected portion,and thus it is possible to perform quick processing.

Hereinafter, details of the database of combinations with suitable toolswill be described. FIG. 46 is a diagram illustrating an example of astable region of a tool. As illustrated in FIG. 46, a curve LL1 is aboundary between a region in which a tool is stable and a region inwhich the tool is unstable during processing. As illustrated in FIG. 46,a lower region of the curve LL1 is a region in which a tool is stableduring, and an upper region of the curve LL1 a region in which the toolis unstable during processing. The stable region under the curve LL1 hasa region called a stable packet in which an upper limit of an axialdirection cutting amount is great according to a spindle rotation speed.The curve LL1 is obtained by solving a determinant formed of a matrixcomponent of cutting force during processing, and a transfer function ofa tool, a raw material, or a material. Measurement of a transferfunction of a tool side and calculation of a matrix component of cuttingforce are possible by using dedicated programs. On the other hand,measurement of a transfer function of a raw material side or a materialside and calculation of a matrix component of cutting force aredifficult since the rigidity or the weight of the raw material side orthe material side is changed during processing, and thus aneigenfrequency changes, in a case where a shape of the raw material sideor the material side is complex.

Therefore, in the present embodiment, a straight line LL2 showing anunconditional stability limit which does not depend on a spindlerotation speed is used in order to generate a tool path for stableprocessing by simply taking into consideration a raw material side or amaterial side. As illustrated in FIG. 46, a region under the straightline LL2 is a region in which a tool is stable during processingregardless of a spindle rotation speed, and a region over the straightline LL2 is a region in which a tool may possibly be unstable duringprocessing depending on a spindle rotation speed. The straight line LL2showing an unconditional stability limit is required to be calculatedanalytically on the basis of the maximum negative real part of thetransfer function.

Thus, in the present embodiment, an approximate value of the staticrigidity of a raw material side or a material side, and cutting power orcutting force calculated on the basis of cutting conditions areobtained, a power ratio which is a ratio between the cutting power of atool and the approximate value of the static rigidity of the rawmaterial side and the material side, and a tilt amount which is a ratiobetween the cutting force of the tool and the approximate value of thestatic rigidity of the raw material side and the material side arecalculated, conditions in which the tool is stable during processing areset on the basis of the power ratio and the tilt amount, and cuttingconditions are set on the basis of the conditions.

FIG. 47 is a diagram illustrating roughing tool conditions 83 which areexamples of a combination of a spindle rotation speed of a tool and afeed amount per tooth in roughing. FIG. 48 is a diagram illustratingfinishing tool conditions 84 which are example of a combination of aspindle rotation speed of a tool and a feed amount per tooth infinishing. As illustrated in FIG. 47, the roughing tool conditions 83include a plurality of combinations of the kind of tool in roughing, acondition serial number n, a spindle rotation speed S (unit: min⁻¹), afeed amount fz per tooth (unit: mm/tooth), an axial direction cuttingamount Ad (unit: mm), a radial direction cutting amount Rd (unit: mm).As illustrated in FIG. 48, the finishing tool conditions 84 include aplurality of combinations of the kind of tool in roughing, a conditionserial number n, a spindle rotation speed S (unit: min⁻¹), a feed amountfz per tooth (unit: mm/tooth), an axial direction cutting amount Ad(unit: mm), a radial direction cutting amount Rd (unit: mm).

The kind of tool is included in the combinations of the roughing toolconditions 83 and the finishing tool conditions 84, as symbols such asA, B, . . . added to tools. The condition serial number n is a serialnumber added to each condition, such as 1, 2, 3, 4, . . . . Thecondition serial number n is added in an order of the spindle rotationspeed S being higher in the same kind of tool. The spindle rotationspeed S is a rotation speed of a spindle of a tool per minute. Thespindle rotation speed S is set to a predefined value including a stablepacket in the roughing tool conditions 83 and the finishing toolconditions 84 from the viewpoint of stability of processing.Specifically, the spindle rotation speed S is set to each value obtainedby dividing 30000 min⁻¹ by an integer of 2 or greater in the roughingtool conditions 83 and the finishing tool conditions 84. The feed amountfz per tooth is a feed amount of a tool in a radial direction fromcontact of a certain tooth with a raw material or a material to contactof the next tooth with the raw material or the material. The axialdirection cutting amount Ad is a processing amount (processing length)in a direction parallel to an axial direction of a tool in processingperformed once. The radial direction cutting amount Rd is a processingamount (processing length) in a direction parallel to a radial directionof a tool in processing performed once.

The control section 12 c temporarily sets a combination of the spindlerotation speed S and the feed amount fz per tooth of the tool used formachining, selected in step S102 in each of roughing and finishing (stepS104). Specifically, in a case where the tool A is selected in stepS102, the control section 12 c temporarily sets, for example, acombination of the spindle rotation speed S and the feed amount fz pertooth in a combination with the lowest condition serial number n. In acase where the roughing tool conditions 83 and the finishing toolconditions 84 are used, the control section 12 c temporarily sets thecombination in a combination with the condition serial number n of 1,that is, a combination of the spindle rotation speed S of 15000 min⁻¹and the feed amount fz per tooth of 0.1 mm/tooth.

After step S104, the control section 12 c temporarily sets the axialdirection cutting amount Ad and the radial direction cutting amount Rdin roughing and finishing by using information regarding the shape andinformation regarding the substance of the material design model 70 orthe raw material design model 80 included in the cutting conditionsetting element (step S105). Hereinafter, a specific method oftemporarily setting the axial direction cutting amount Ad and the radialdirection cutting amount Rd will be described in detail by using anexample of processing the raw material design model 80. FIG. 49 is adiagram illustrating an example of an order of processing of the mainplate raw material portion in the raw material design model 80. FIG. 50is a diagram illustrating an example of an order of processing of theflange raw material portion in the raw material design model 80. InFIGS. 49 and 50, although not illustrated, the grip portion v isprovided on the lower side in the drawing surface. In processing of themain plate raw material portion, the control section 12 c temporarilysets a processing order to be a processing order corresponding tonumerical values illustrated in FIG. 49 such that processing isperformed from a farther side from the grip portion v toward a closerside thereto, that is, from the upper side in the drawing surface towardthe lower side. In processing of the flange raw material portion, thecontrol section 12 c temporarily sets a processing order to be aprocessing order corresponding to numerical values illustrated in FIG.50 such that processing is performed from a farther side from the mainplate portion toward a closer side thereto, that is, from a distal endside of the flange raw material portion toward a basal end side thereof.

Specifically, the control section 12 c temporarily sets a processingorder in the main plate raw material portion of the raw material designmodel 80 such that roughing is performed on both surfaces of the mainplate raw material portion as indicated by Nos. 1 and 2 in FIG. 49, andthen finishing is performed twice on each of both of the surfaces of themain plate raw material portion from the farther side from the gripportion v toward the closer side thereto as indicated by Nos. 3, 4, 5,and 6 in FIG. 49. The control section 12 c temporarily sets a processingorder in the main plate raw material portion of the raw material designmodel 80 such that roughing and finishing are also performed on alocation closer to the grip portion v than Nos. 1 to 6 in FIG. 49 in thesame conditions and order than those of Nos. 1 to 6 in FIG. 49. Asillustrated in FIG. 49, in the main plate raw material portion of theraw material design model 80, the control section 12 c temporarily setsthe axial direction cutting amount Ad in roughing to a height h_(wr) ina direction parallel to the height direction of the main plate rawmaterial portion, and the radial direction cutting amount Rd in roughingto a thickness ((T_(w)−t_(wr))/2) along the plate thickness direction ofthe main plate raw material portion. As illustrated in FIG. 49, in themain plate raw material portion of the raw material design model 80, thecontrol section 12 c temporarily sets the axial direction cutting amountAd in finishing to a height h_(wr)/2 in the direction parallel to theheight direction of the main plate raw material portion, and the radialdirection cutting amount Rd in finishing to a thickness((t_(wr)−t_(w))/2) along the plate thickness direction of the main plateraw material portion. Consequently, the control section 12 c temporarilysets a tool path until the main plate raw material portion of the rawmaterial design model 80 is processed to have the same thickness as theplate thickness t_(w) of the main plate portion of the material designmodel 70.

In the present embodiment, the control section 12 c divides processingof the main plate raw material portion of the raw material design model80 into two stages such as roughing and finishing in the directionparallel to the plate thickness direction of the main plate raw materialportion as illustrated in FIG. 49, and temporarily sets a platethickness of the main plate raw material portion after the roughing tothe plate thickness t_(wr), but is not limited thereto, and may dividethe processing into three or more stages. In a case where processing isdivided into two stages as in the present embodiment, the controlsection 12 c preferably temporarily sets the plate thickness t_(wr) suchthat a ratio between the thickness ((T_(w)−t_(wr))/2) which is theradial direction cutting amount Rd in roughing and the thickness((t_(wr)−t_(w))/2) which is the radial direction cutting amount Rd infinishing is an inverse number of a parameter based on a substance,which is predefined according to the rigidity of the substance. Forexample, in a case where the substance is aluminum, the control section12 c preferably temporarily sets the plate thickness t_(wr) such that aratio between the thickness ((T_(w)−t_(wr))/2) and the thickness((t_(wr)−t_(w))/2) is 5 which is an inverse number of ⅕. In this case,it is possible to increase a yield of processing, and also to quicklyperform processing.

In the present embodiment, the control section 12 c divides processingof the main plate raw material portion of the raw material design model80 into three stages in the direction along the main plate raw materialportion as illustrated in FIG. 49, but is not limited thereto, and thecontrol section 12 c may not divide the processing, may divide theprocessing into two stages, and may divide the processing into four ormore stages. In a case of the present embodiment, the control section 12c preferably temporarily sets the height h_(wr) and the plate thicknesst_(wr) such that a ratio between the height h_(wr) which is a heightalong the main plate raw material portion in a processing region duringroughing and the plate thickness t_(wr) which is a thickness along theplate thickness direction of the main plate raw material portion in theprocessing region after the roughing is an inverse number of a parameterbased on a substance, which is predefined according to the rigidity ofthe substance. The control section 12 c preferably temporarily sets theheight h_(wr) such that a ratio between the height h_(wr)/2 which is aheight along the main plate raw material portion in a processing regionduring finishing and the plate thickness t_(w) which is a thicknessalong the plate thickness direction of the main plate raw materialportion in the processing region during the finishing is an inversenumber of a parameter based on a substance, which is predefinedaccording to the rigidity of the substance. Also in this case, forexample, in a case where the substance is aluminum, the control section12 c preferably temporarily sets the plate thickness t_(wr) such that aratio between the thickness ((T_(w)−t_(wr))/2) and the thickness((t_(wr)−t_(w))/2) is 5 which is an inverse number of ⅕. In this case,it is possible to increase a yield of processing, and also to quicklyperform processing.

Alternatively, in a case where a division stage number of finishing inthe direction along the main plate raw material portion for roughing isindicated by X, the control section 12 c preferably temporarily sets Xsuch that a ratio between the height h_(wr)/X which is a height alongthe main plate raw material portion in a processing region duringfinishing and the plate thickness t_(w) which is a thickness along theplate thickness direction of the main plate raw material portion in theprocessing region after the finishing is an inverse number of aparameter based on a substance, which is predefined according to therigidity of the substance. Also in this case, for example, in a casewhere the substance is aluminum, the control section 12 c preferablytemporarily sets X such that a ratio between the thickness((T_(w)−t_(wr))/2) and the thickness ((t_(wr)−t_(w))/2) is 5 which is aninverse number of ⅕. In this case, it is possible to increase a yield ofprocessing, and also to quickly perform processing.

The control section 12 c temporarily sets a processing order in theflange raw material portion of the raw material design model 80 suchthat roughing is performed on both surfaces of the flange raw materialportion as indicated by Nos. 1 and 2 in FIG. 50, and then finishing isperformed twice on each of both of the surfaces of the main plate rawmaterial portion from the farther side from the main plate raw materialportion toward the closer side thereto as indicated by Nos. 3, 4, 5, and6 in FIG. 50. The control section 12 c temporarily sets a processingorder in the flange raw material portion of the raw material designmodel 80 such that roughing and finishing are also performed on alocation closer to the main plate portion than Nos. 1 to 6 in FIG. 50,for example, Nos. 7 to 12 in FIG. 50 in the same conditions and orderthan those of Nos. 1 to 6 in FIG. 50. As illustrated in FIG. 50, in theflange raw material portion of the raw material design model 80, thecontrol section 12 c temporarily sets the axial direction cutting amountAd in roughing to a height h_(fr) in a direction parallel to the heightdirection of the flange raw material portion, and the radial directioncutting amount Rd in roughing to a thickness ((T_(f)−t_(fr))/2) alongthe plate thickness direction of the flange raw material portion. Asillustrated in FIG. 50, in the flange raw material portion of the rawmaterial design model 80, the control section 12 c temporarily sets theaxial direction cutting amount Ad in finishing to a height h_(fr)/2 inthe direction parallel to the height direction of the flange rawmaterial portion, and the radial direction cutting amount Rd infinishing to a thickness ((t_(fr)−t_(f))/2) along the plate thicknessdirection of the flange raw material portion. Consequently, the controlsection 12 c temporarily sets a tool path until the flange raw materialportion of the raw material design model 80 is processed to have thesame thickness as the plate thickness t_(f) of the flange of thematerial design model 70.

In the present embodiment, the control section 12 c divides processingof the flange raw material portion of the raw material design model 80into two stages such as roughing and finishing in the direction parallelto the plate thickness direction of the flange raw material portion asillustrated in FIG. 50, and temporarily sets a plate thickness of theflange raw material portion after the roughing to the plate thicknesst_(fr), but is not limited thereto, and may divide the processing intothree or more stages. In a case where processing is divided into twostages as in the present embodiment, the control section 12 c preferablytemporarily sets the plate thickness t_(fr) such that a ratio betweenthe thickness ((T_(f)−t_(fr))/2) which is the radial direction cuttingamount Rd in roughing and the thickness ((t_(fr)−t_(f))/2) which is theradial direction cutting amount Rd in finishing is an inverse number ofa parameter based on a substance, which is predefined according to therigidity of the substance. For example, in a case where the substance isaluminum, the control section 12 c preferably temporarily sets the platethickness t_(fr) such that a ratio between the thickness((T_(f)−t_(fr))/2) and the thickness ((t_(fr)−t_(f))/2) is 5 which is aninverse number of ⅕. In this case, it is possible to increase a yield ofprocessing, and also to quickly perform processing.

In the present embodiment, the control section 12 c divides processingof the flange raw material portion of the raw material design model 80into three stages in the direction along the flange raw material portionas illustrated in FIG. 50, but is not limited thereto, and the controlsection 12 c may not divide the processing, may divide the processinginto two stages, and may divide the processing into four or more stages.In a case of the present embodiment, the control section 12 c preferablytemporarily sets the height h_(fr) and the plate thickness t_(fr) suchthat a ratio between the height h_(fr) which is a height along theflange raw material portion in a processing region during roughing andthe plate thickness t_(fr) which is a thickness along the platethickness direction of the flange raw material portion in the processingregion after the roughing is an inverse number of a parameter based on asubstance, which is predefined according to the rigidity of thesubstance. The control section 12 c preferably temporarily sets theheight h_(fr) such that a ratio between the height h_(fr)/2 which is aheight along the flange raw material portion in a processing regionduring finishing and the plate thickness t_(f) which is a thicknessalong the plate thickness direction of the flange raw material portionin the processing region during the finishing is an inverse number of aparameter based on a substance, which is predefined according to therigidity of the substance. Also in this case, for example, in a casewhere the substance is aluminum, the control section 12 c preferablytemporarily sets the plate thickness t_(fr) and X such that a ratiobetween the thickness ((T_(f)−t_(fr))/2) and the thickness((t_(fr)−t_(f))/2) is 5 which is an inverse number of ⅕. In this case,it is possible to increase a yield of processing, and also to quicklyperform processing.

Alternatively, in a case where a division stage number of finishing inthe direction along the flange raw material portion for roughing isindicated by X, the control section 12 c preferably temporarily sets Xsuch that a ratio between the height h_(fr)/X which is a height alongthe flange raw material portion in a processing region during finishingand the plate thickness t_(f) which is a thickness along the platethickness direction of the flange raw material portion in the processingregion after the finishing is an inverse number of a parameter based ona substance, which is predefined according to the rigidity of thesubstance. Also in this case, for example, in a case where the substanceis aluminum, the control section 12 c preferably temporarily sets X suchthat a ratio between the thickness ((T_(f)−t_(fr))/2) and the thickness((t_(fr)−t_(f))/2) is 5 which is an inverse number of ⅕. In this case,it is possible to increase a yield of processing, and also to quicklyperform processing.

After the process of step S105, the control section 12 c determineswhether or not the axial direction cutting amount Ad and the radialdirection cutting amount Rd which are temporarily set in step S105 arewithin a specification of the tool which is temporarily set in step S104(step S107). Specifically, the control section 12 c determines whetheror not the axial direction cutting amount Ad and the radial directioncutting amount Rd in each of roughing and finishing which aretemporarily set in step S105 are respectively equal to or smaller thanthe axial direction cutting amount Ad and the radial direction cuttingamount Rd combined with the spindle rotation speed S and the feed amountfz per tooth which are temporarily set in step S104. In a case where thetemporarily set axial direction cutting amount Ad and radial directioncutting amount Rd are within the specification of the tool (Yes in stepS107), the control section 12 c causes the process to proceed to stepS111. On the other hand, in a case where the temporarily set axialdirection cutting amount Ad and radial direction cutting amount Rdexceeds the specification of the tool (No in step S107), the controlsection 12 c corrects the temporarily set axial direction cutting amountAd and radial direction cutting amount Rd to values within thespecification of the tool (step S108), and causes the process to proceedto step S111. In a case where the process of step S108 is performed, thecontrol section 12 c may correct the temporarily set axial directioncutting amount Ad and radial direction cutting amount Rd to valueswithin the specification of the tool by increasing the number of stagesinto which processing is divided.

In the tool path for roughing and the tool path for finishing which aretemporarily set in step S105, the control section 12 c calculates shapesof processing regions in each roughing and each finishing by using theinformation regarding the shape and the information regarding thesubstance of the material design model 70 or the raw material designmodel 80 included in the cutting condition setting element (step S111).Specifically, in a case where the processing region is included in themain plate raw material portion, the control section 12 c calculates aheight along the main plate raw material portion from a front end of theprocessing region to the grip portion v. For example, in a case whereany one of Nos. 1, 2, 3, and 4 illustrated in FIG. 49 is a processingregion, the control section 12 c calculates H_(wR) corresponding to theheight. In a case where the processing region is included in the flangeraw material portion, the control section 12 c calculates a height alongthe flange raw material portion from a front end of the processingregion to an end opposite side the processing region of the main plateraw material portion. For example, in a case where any one of Nos. 1, 2,3, and 4 illustrated in FIG. 50 is a processing region, the controlsection 12 c calculates H_(fR) corresponding to the height.

After the process of step S111, the control section 12 c calculates anapproximate value of the static rigidity in each roughing and eachfinishing, that is, an approximate value of the static rigidity of theraw material or the material when the processing region is processed, byusing the information regarding the shape and the information regardingthe substance of the material design model 70 or the raw material designmodel 80 included in the cutting condition setting element, on the basisof the shapes of the processing regions in each roughing and eachfinishing which are calculated in step S111 (step S112). In the processof step S112, the control section 12 c calculates an approximate valueof the static rigidity of an element which may be influenced duringprocessing in the raw material or the material when the processingregion is processed. Hereinafter, details of a method of calculating anapproximate value of the static rigidity of the raw material or thematerial when the processing region is processed in the process of stepS112 will be described by using an example of processing a firstprocessing region of the raw material design model 80 illustrated inFIG. 49 and an example of processing a first processing region of theraw material design model 80 illustrated in FIG. 50.

In a case of processing the first processing region of the raw materialdesign model 80 illustrated in FIG. 49, a sectional secondary momentI_(wr) regarding an axial direction in roughing is obtained according tothe following Equation 1 by using the length l of the main plate portionof the material design model 70 and the plate thickness T_(w) of themain plate raw material portion of the raw material design model 80.I _(wr) =lT _(w) ³/12  (1)

In a case where the first processing region of the raw material designmodel 80 illustrated in FIG. 49 is processed, an approximate valuek_(wr) of the static rigidity in roughing is obtained according to thefollowing Equation 2 by using the Young's modulus E of the raw material,H_(wR) calculated in step S111, and the sectional secondary momentI_(wr) obtained according to Equation 1.k _(wr)=3EI _(wr) /H _(wR) ³  (2)

In a case of processing the first processing region of the raw materialdesign model 80 illustrated in FIG. 49, a sectional secondary momentI_(wf) regarding an axial direction in finishing is obtained accordingto the following Equation 3 by using the length l of the main plateportion of the material design model 70 and the plate thickness t_(wr)of the main plate raw material portion of the raw material design model80 after roughing.I _(wf) =lt _(wr) ³/12  (3)

In a case where the processing region of the raw material design model80 illustrated in FIG. 49 is processed, an approximate value k_(wf) ofthe static rigidity in finishing is obtained according to the followingEquation 4 by using the Young's modulus E of the raw material, H_(wR)calculated in step S111, h_(wr) set in step S105, the sectionalsecondary moment I_(wr) obtained according to Equation 1, and thesectional secondary moment I_(wf) obtained according to Equation 3.k _(wf)=3EI _(wr) I _(wf)/(I _(wr) H _(wR) ³ −I _(wr) h _(wr) ³ +I _(wf)h _(wr) ³)  (4)

In a case of processing the first processing region of the raw materialdesign model 80 illustrated in FIG. 50, a sectional secondary momentI_(fw) regarding the axial direction of the main plate raw materialportion in roughing and finishing is obtained according to the followingEquation 5 by using the length l of the main plate portion of thematerial design model 70 and the plate thickness T_(w) of the main plateraw material portion of the raw material design model 80.I _(fw) =lT _(w) ³/12  (5)

In a case of processing the first processing region of the raw materialdesign model 80 illustrated in FIG. 50, a sectional secondary momentI_(fr) regarding the axial direction of the flange raw material portionin roughing is obtained according to the following Equation 6 by usingthe length l of the main plate portion of the material design model 70,and the plate thickness T_(f) of the flange raw material portion of theraw material design model 80.I _(fr) =lT _(f) ³/12  (6)

In a case where the processing region of the raw material design model80 illustrated in FIG. 50 is processed, an approximate value k_(fr) ofthe static rigidity in roughing is obtained according to the followingEquation 7 by using the Young's modulus E of the raw material, H_(wR)calculated in step S111, H_(fR) calculated in step S111, the sectionalsecondary moment I_(fw) obtained according to Equation 5, and thesectional secondary moment I_(fr) obtained according to Equation 6.k _(fr)=3EI _(fw) I _(fr)/(H _(fR) ²(3I _(fr) H _(wR) +I _(fw) H_(fR)))  (7)

In a case of processing the first processing region of the raw materialdesign model 80 illustrated in FIG. 50, a sectional secondary momentI_(ff) regarding the axial direction of the flange raw material portionin finishing is obtained according to the following Equation 8 by usingthe length l of the main plate portion of the material design model 70,and the plate thickness t_(fr) of the flange raw material portion of theraw material design model 80 after roughing.I _(ff) =lt _(fr) ³/12  (8)

In a case where the first processing region of the raw material designmodel 80 illustrated in FIG. 50 is processed, an approximate valuek_(ff) of the static rigidity in finishing is obtained according to thefollowing Equation 9 by using the Young's modulus E of the raw material,H_(wR) calculated in step S111, H_(fR) calculated in step S111, h_(fr)set in step S105, the sectional secondary moment I_(fw) obtainedaccording to Equation 5, the sectional secondary moment I_(fr) obtainedaccording to Equation 6, and the sectional secondary moment I_(ff)obtained according to Equation 8.k _(ff)=3EI _(fr) I _(ff) I _(fw)/(3H _(fR) ² H _(wR) I _(fr) I _(ff) +H_(fR) ³ I _(ff) I _(fw) −h _(fr) ³ I _(ff) I _(fw) +h _(fr) ³ I _(fr) I_(fw))   (9)

As mentioned above, in the process of step S112, the control section 12c can calculate the approximate value k_(wr) of the static rigidity inroughing and the approximate value k_(wf) of the static rigidity infinishing in a case where the first processing region of the rawmaterial design model 80 illustrated in FIG. 49 is processed, and theapproximate value k_(fr) of the static rigidity in roughing and theapproximate value k_(ff) of the static rigidity in finishing in a casewhere the first processing region of the raw material design model 80illustrated in FIG. 50 is processed. By using the same methods asdescribed above, the control section 12 c calculates an approximatevalue of the static rigidity in roughing and an approximate value of thestatic rigidity in finishing in all processing regions included in aregion for which the tool path selected in step S101 is generatedthrough the process of step S112.

After the process of step S112, the control section 12 c calculatescutting force on the basis of the spindle rotation speed S and the feedamount fz per tooth of the tool which are temporarily set in step S104,and the axial direction cutting amount Ad and the radial directioncutting amount Rd which are temporarily set in step S105 or step S108(step S113). Hereinafter, details of a method of calculating cuttingforce in the process of step S113 will be described.

Cutting power Pc required to calculate cutting force Fc is obtained asin the following Equation 10 by using the axial direction cutting amountAd temporarily set in step S105 or step S108, the radial directioncutting amount Rd temporarily set in step S105 or step S108, a feedamount F of the tool, and a specific cutting resistance Kc.Pc=(Rd×Ad×F×Kc)/(60×10⁶) [kW]  (10)

Here, the feed amount F of the tool is expressed as in the followingEquation 11 by using the spindle rotation speed S of the tooltemporarily set in step S104, the feed amount fz per tooth of the tooltemporarily set in step S104, and the number N of teeth of the tool.F=S×fz×N[mm/min]  (11)

FIG. 51 is a diagram illustrating an example of a relationship betweenthe feed amount fz per tooth and the specific cutting resistance Kc. Thespecific cutting resistance Kc has a relationship of being attenuatedaccording to the feed amount fz per tooth as illustrated in FIG. 51. Arelationship between the specific cutting resistance Kc and the feedamount fz per tooth is determined depending on a combination of a tooland a raw material or a material. A representative relationship may beused as a relationship between the specific cutting resistance Kc andthe feed amount fz per tooth. In the present embodiment, in a case wherethe control section 12 c has data regarding a relationship determineddepending on a combination of a tool and a raw material or a material,the specific cutting resistance Kc may be calculated on the basis of thefeed amount fz per tooth by using the relationship. In the presentembodiment, in a case where the control section 12 c does not have dataregarding a relationship determined depending on a combination of a tooland a raw material or a material, the specific cutting resistance Kc maybe calculated on the basis of the feed amount fz per tooth by using arelationship which is most appropriate for a combination of a tool and araw material or a material among representative relationships.

The cutting force Fc is calculated by using the cutting power Pcexpressed in Equation 10, and a cutting velocity Vc. The cuttingvelocity Vc is expressed as in the following Equation 12 by using a tooldiameter, that is, a diameter Da of the tool and the spindle rotationspeed S of the tool.Vc=πDa×S/1000 [m/min]  (12)

The cutting force Fc is obtained according to the following Equation 13by using the cutting power Pc expressed in Equation 10 and the cuttingvelocity Vc expressed in Equation 12.Fc=Pc/Vc=(Rd×Ad×fz×N×Kc)πDa[N]  (13)

As mentioned above, the control section 12 c may calculate the cuttingforce Fc of the tool through the process of step S113.

After the process of step S113, the control section 12 c calculates atilt amount δ on the basis of the approximate value of the staticrigidity in each of roughing and finishing calculated in step S112, andthe cutting force Fc calculated in step S113 (step S114). Specifically,in a case where all kinds of approximate values of the static rigidityare collectively indicated by k, the control section 12 c calculates thetilt amount δ (unit: μm) according to the following Equation 14 by usingthe approximate value k of the static rigidity and the cutting force Fc.The tilt amount δ is a ratio between the cutting force Fc and theapproximate value k of the static rigidity.δ=Fc/k×1000  (14)

After the process of step S114, the control section 12 c determineswhether or not the tilt amount δ is within a threshold value (stepS116). In a case where the tilt amount δ in roughing is determined, thecontrol section 12 c determines whether or not the tilt amount δ inroughing is equal to or smaller than a threshold value δr of the tiltamount in roughing. In a case where the tilt amount δ in finishing isdetermined, the control section 12 c determines whether or not the tiltamount δ in finishing is equal to or smaller than a threshold value δfof the tilt amount in finishing which is different from the thresholdvalue δr of the tilt amount in roughing. The threshold value δr of thetilt amount in roughing is greater than the threshold value δf of thetilt amount in finishing. The control section 12 c preferably sets aratio between the threshold value δr of the tilt amount in roughing andthe threshold value δf of the tilt amount in finishing to an inversenumber of a parameter based on a substance, predefined according to therigidity of the substance. For example, in a case where the substance isaluminum, the control section 12 c preferably sets a ratio between thethreshold value δr of the tilt amount in roughing and the thresholdvalue δf of the tilt amount in finishing to 5 which is an inverse numberof ⅕. In this case, it is possible to increase a yield of processing,and also to quickly perform processing. Specifically, the thresholdvalue δr of the tilt amount in roughing and the threshold value δf ofthe tilt amount in finishing are preferably respectively, for example,100 μm and 20 μm. In the process of step S116, the control section 12 cperforms separate determinations in roughing and in finishing.

In a case where the tilt amount δ is within the threshold value (Yes instep S116), the control section 12 c causes process to proceed to stepS121. On the other hand, in a case where the tilt amount δ is not withinthe threshold value (No in step S116), the control section 12 c performscorrection of reducing the feed amount fz per tooth, the axial directioncutting amount Ad, and the radial direction cutting amount Rd which aretemporarily set (step S117), and performs the processes of step S111 tostep S116 on the basis of the corrected feed amount fz per tooth, axialdirection cutting amount Ad, and radial direction cutting amount Rd. Ina case where the tilt amount δ in one of roughing and finishing iswithin the threshold value (Yes in step S116), and the tilt amount δ inthe other processing is not within the threshold value (No in stepS116), the control section 12 c performs the process of step S121 in thecase where the tilt amount δ in one of roughing and finishing is withinthe threshold value, and performs the process of the step S117 and theprocesses of step S111 to step S116 in the case where the tilt amount δin the other processing is not within the threshold value. The controlsection 12 c repeatedly performs the process of step S117 and theprocesses of step S111 to step S116 until it is determined that the tiltamount δ is within the threshold value.

In a case where the tilt amount δ is within the threshold value (Yes instep S116), the control section 12 c calculates a power ratiocounterclockwise-T on the basis of the approximate value of the staticrigidity in each of roughing and finishing, calculated in step S112, andthe cutting power Pc calculated in step S113 (step S121). Specifically,in a case where all kinds of approximate values of the static rigidityare collectively indicated by k, the control section 12 c calculates thepower ratio counterclockwise-T according to the following Equation 15 byusing the approximate value k of the static rigidity and the cuttingpower Pc. The power ratio counterclockwise-T is a ratio between thecutting power Pc and the approximate value k of the static rigidity.counterclockwise-T=Pc/k×1000  (15)

After the process of step S121, the control section 12 c determineswhether or not the power ratio counterclockwise-T is within a thresholdvalue (step S122). In a case where the power ratio counterclockwise-T inroughing is determined, the control section 12 c determines whether ornot the power ratio counterclockwise-T in roughing is equal to or lessthan a threshold value counterclockwise-Tr of the power ratio inroughing. In a case where the power ratio counterclockwise-T infinishing is determined, the control section 12 c determines whether ornot the power ratio counterclockwise-T in finishing is equal to or lessthan a threshold value counterclockwise-Tf of the power ratio infinishing, which is different from the threshold valuecounterclockwise-Tr of the power ratio in roughing. The threshold valuecounterclockwise-Tr of the power ratio in roughing is greater than thethreshold value counterclockwise-Tf of the power ratio in finishing. Thecontrol section 12 c preferably sets a ratio between the threshold valuecounterclockwise-Tr of the power ratio in roughing and the thresholdvalue counterclockwise-Tf of the power ratio in finishing to an inversenumber of a parameter based on a substance, predefined according to therigidity of the substance. For example, in a case where the substance isaluminum, the control section 12 c preferably sets a ratio between thethreshold value counterclockwise-Tr of the power ratio in roughing andthe threshold value counterclockwise-Tf of the power ratio in finishingto 5 which is an inverse number of ⅕. In this case, it is possible toincrease a yield of processing, and also to quickly perform processing.Specifically, the threshold value counterclockwise-Tr of the power ratioin roughing and the threshold value counterclockwise-Tf of the powerratio in finishing are preferably respectively, for example, 0.6 and0.12. In the process of step S122, the control section 12 c performsseparate determinations in roughing and in finishing.

In a case where the power ratio counterclockwise-T is within thethreshold value (Yes in step S122), the control section 12 c generates atool path for the region selected in step S101 on the basis of thetemporarily set conditions (step S125), and causes the process toproceed to step S126. On the other hand, in a case where the power ratiocounterclockwise-T is not within the threshold value (No in step S122),the control section 12 c performs correction of adding 1 to thecondition serial number n attached to the combination of the spindlerotation speed S and the feed amount fz per tooth of the selected tool(step S123), and performs the processes of step S111 to step S122 on thebasis of the corrected spindle rotation speed S and feed amount fz pertooth. In a case where the power ratio counterclockwise-T in one ofroughing and finishing is within the threshold value (Yes in step S122),and the power ratio counterclockwise-T in the other processing is notwithin the threshold value (No in step S122), the control section 12 cperforms the process of step S125 in the case where the power ratiocounterclockwise-T in one of roughing and finishing is within thethreshold value, and performs the process of step S123 and the processesof step S111 to step S122 in the case where the power ratiocounterclockwise-T in the other processing is not within the thresholdvalue. The control section 12 c repeatedly performs the process of stepS123 and the processes of step S111 to step S122 until it is determinedthat the power ratio counterclockwise-T is within the threshold value.

FIG. 52 is a diagram illustrating an example of cutting conditioncalculation. In a case where a tool path for the region selected in stepS101 is generated, as illustrated in FIG. 52, the control section 12 cdetermines the axial direction cutting amount Ad and the radialdirection cutting amount Rd in each of roughing and finishing, anddetermines a plate thickness and a height of a processing region in araw material before roughing, a plate thickness and a height of theprocessing region after roughing and finishing, and a plate thicknessand a height of a processing region in a material after finishing.

After the process of step S125, the control section 12 c determineswhether or not tool paths have been generated for all regions (stepS126). Specifically, the control section 12 c determines whether or nottool paths have been generated for all elements by using the cuttingcondition setting element among the elements read in step S64. In a casewhere tool paths have been generated for all regions (Yes in step S126),the control section 12 c finishes the process of tool path generationstep S66, and causes the process to proceed to tool path connection stepS67 illustrated in FIG. 28. On the other hand, in a case where toolpaths have not been generated for all regions (No in step S126), thecontrol section 12 c causes the process to proceed to step S101, selectsa region for which a tool path is not generated (step S101), performsthe processes of step S102 to step S125 on the selected new region asdescribed above, and then performs the process of step S126 thereon. Thecontrol section 12 c repeatedly performs the processes of step S101 tostep S126 until tool paths for all regions are generated.

Referring to FIG. 28 again, after the process of step S66, the controlsection 12 c connects the tool paths generated for the respectiveelements in step S66, so as to create the numerical control program 19(step S67). Specifically, the control section 12 c connects the toolpaths generated for the respective elements in step S66 on the basis ofthe processing order included in the tool path generation elementcreated in step S78, so as to create the numerical control program 19.In other words, the control section 12 c connects tool pathscorresponding to elements far from the grip portion v and tool pathscorresponding to elements close thereto to each other in this order. Thecontrol section 12 c connects a tool path corresponding to an elementincluding the flange, a tool path corresponding to an element includingthe cross part, and a tool path corresponding to an element includingthe main plate portion to each other in this order. The control section12 c connects a tool path corresponding to an element including an endsurface along a direction orthogonal to the axial direction and a toolpath corresponding to an element including a surface along the axialdirection to each other in this order. With respect to the tool pathcorresponding the element including the cross part and the tool pathcorresponding to the element including the main plate portion, thecontrol section 12 c may sequentially connect the tool pathscorresponding to the elements to each other as a whole in an order ofbeing far from the grip portion v.

After the process of step S67, the control section 12 c verifies whetheror not the raw material or the material, a grip member gripping the rawmaterial or the material, and a tool processing the raw material or thematerial physically interfere with each other in a case where thenumerical control program 19 created in step S67 is executed by thecontrol section 13 c of the machining device 13 (step S69). In a casewhere it is determined that physical interference occurs in the processof step S69, the control section 12 c corrects the numerical controlprogram 19 such that the physical interference does not occur. In a casewhere it is determined that physical interference does not occur in theprocess of step S69, the control section 12 c verifies that physicalinterference does not occur without correcting the numerical controlprogram 19. After the process of step S69, the control section 12 cperforms a post-process which is a process of enabling the numericalcontrol program 19 to be executed by the control section 13 c of themachining device 13 on the numerical control program 19, and acquiresthe numerical control program 19 which can be executed by the controlsection 13 c of the machining device 13. Consequently, the controlsection 12 c finishes a series of flows of the numerical control programgeneration method.

In the numerical control program generation system 12, the numericalcontrol program generation program 16, and the numerical control programgeneration method processed thereby according to the present embodiment,the control section 12 c uses an element regarding a shape of a materialcreated in element creation step S62 for tool path generation step S66of a tool path in which a route of a processing operation is coded,through element reading step S64. Thus, in the numerical control programgeneration system 12, the numerical control program generation program16, and the numerical control program generation method processedthereby according to the present embodiment, a cutting conditioncorresponding to a processing shape can be set, and thus it is possibleto generate a tool path in which a route of a processing operation iscoded according to the processing shape.

In the numerical control program generation system 12, the numericalcontrol program generation program 16, and the numerical control programgeneration method processed thereby according to the present embodiment,the control section 12 c may compare the material design model 70 withthe similar material design model 74, and create an element bycorrelating corresponding portions of the material design model 70 andthe similar material design model 74 with each other, in elementcreation step S62, read a similarity and a difference between thecorrelated portions in element creation step S62 in element reading stepS64, and use a tool path generated on the basis of the similar materialdesign model 74 as a tool path corresponding to an element including thesimilarity, and generate a tool path to which a tool path generated onthe basis of the similar material design model 74 is changed accordingto the difference, as a tool path corresponding to an element includingthe difference, in the tool path generation step S66. Thus, in thenumerical control program generation system 12, the numerical controlprogram generation program 16, and the numerical control programgeneration method processed thereby according to the present embodiment,it is possible to highly accurately create the numerical control program19 regarding processing of a material having a large number ofconsiderably similar shapes.

In the numerical control program generation system 12, the numericalcontrol program generation program 16, and the numerical control programgeneration method processed thereby according to the present embodiment,the control section 12 c may select the similar material design model 74in element creation step S62 on the basis of at least one of the rawmaterial used for the material, the type and a size of a shape of thematerial design model 70, an angle of a flange provided in the materialdesign model 70, the extent of change in the plate thickness t_(f) ofthe flange, and the presence or absence of the mouse hole MH. Thus, inthe numerical control program generation system 12, the numericalcontrol program generation program 16, and the numerical control programgeneration method processed thereby according to the present embodiment,it is possible to select the similar material design model 74 with highaccuracy.

In the numerical control program generation system 12, the numericalcontrol program generation program 16, and the numerical control programgeneration method processed thereby according to the present embodiment,in the element creation step S62, the control section 12 c may extractsurface elements included in the raw material or the material, set asurface element including a straight line corresponding to the longestdistance between two points as the first reference surface 76 among thesurface elements, set a surface element including a straight linecorresponding to the longest distance between two points as the secondreference surface 77 among surface elements orthogonal to the firstreference surface 76, create the coordinate axes 78 having anintersection line between the first reference surface 76 and the secondreference surface 77 as an X axis and any one straight line orthogonalto the first reference surface 76 as a Z axis, and automatically createan element of the raw material or the material by using the createdcoordinate axes 78 as references. Therefore, in the numerical controlprogram generation system 12, the numerical control program generationprogram 16, and the numerical control program generation methodprocessed thereby according to the present embodiment, it is possible toautomatically create an element with high accuracy.

In the numerical control program generation system 12, the numericalcontrol program generation program 16, and the numerical control programgeneration method processed thereby according to the present embodiment,in element creation step S62, the control section 12 c may set surfaceelements, end part elements, an cross part element where two or moresurface elements cross each other, and set some surface elements andcross part elements influenced by the rigidity of the raw material orthe material, as elements for generating a tool path by using thecutting condition setting elements which are elements for settingconditions for a processing operation. Therefore, in the numericalcontrol program generation system 12, the numerical control programgeneration program 16, and the numerical control program generationmethod processed thereby according to the present embodiment, it ispossible to efficiently set a cutting condition for only an element forwhich the cutting condition is required to be set, according to aprocessing shape.

In the numerical control program generation system 12, the numericalcontrol program generation program 16, and the numerical control programgeneration method processed thereby according to the present embodiment,the control section 12 c may read information regarding whether or notan element is set as an element for which a tool path is generated byusing the cutting condition setting elements in element reading stepS64, and create cutting conditions on the basis of the cutting conditionsetting elements with respect to an element set in the cutting conditionsetting elements, and generate a tool path satisfying the cuttingconditions, in tool path generation step S66. Therefore, in thenumerical control program generation system 12, the numerical controlprogram generation program 16, and the numerical control programgeneration method processed thereby according to the present embodiment,it is possible to efficiently set a cutting condition for only anelement for which the cutting condition is required to be set, accordingto a processing shape.

In the numerical control program generation system 12, the numericalcontrol program generation program 16, and the numerical control programgeneration method processed thereby according to the present embodiment,in tool path generation step S66, the control section 12 c may generatecutting conditions on the basis of the power ratio counterclockwise-Twhich is a ratio between the cutting power Pc of a tool used formachining and the approximate value k of the static rigidity of anelement, and the tilt amount δ which is a ratio between the cuttingforce Fc and the approximate value k of the static rigidity. Thus, inthe numerical control program generation system 12, the numericalcontrol program generation program 16, and the numerical control programgeneration method processed thereby according to the present embodiment,it is possible to efficiently set a cutting condition for only anelement for which the cutting condition is required to be set, accordingto a processing shape. In the numerical control program generationsystem 12, the numerical control program generation program 16, and thenumerical control program generation method processed thereby accordingto the present embodiment, it is possible to set a cutting conditioncausing a high yield and also to set a cutting condition causing quickprocessing.

In the numerical control program generation system 12, the numericalcontrol program generation program 16, and the numerical control programgeneration method processed thereby according to the present embodiment,in tool path connection step S67, the control section 12 c may connecttool paths corresponding to elements far from the grip portion v to begripped when the raw material or the material is processed and toolpaths corresponding to elements close thereto to each other in thisorder. Thus, in the numerical control program generation system 12, thenumerical control program generation program 16, and the numericalcontrol program generation method processed thereby according to thepresent embodiment, it is possible to generate the numerical controlprogram 19 causing a high yield of processing of a material.

In the numerical control program generation system 12, the numericalcontrol program generation program 16, and the numerical control programgeneration method processed thereby according to the present embodiment,the control section 12 c may verify whether or not the raw material orthe material, a grip member gripping the raw material or the material,and a tool processing the raw material or the material physicallyinterfere with each other in a case where the numerical control program19 created in step S67 is executed by the control section 13 c of themachining device 13 in numerical control program verification step S69after tool path connection step S67. Thus, it is possible to verifywhether or not the numerical control program 19 will be appropriatelyused before being used for processing of the raw material or thematerial.

In the element creation method in element creation step S62 according tothe present embodiment may be performed such that all plane elements areextracted, a plane element including a straight line corresponding tothe longest distance between two points is set as the first referencesurface 76 among the plane elements, a plane element including astraight line corresponding to the longest distance between two pointsis set as the second reference surface 77 among plane elementsorthogonal to the first reference surface 76, the coordinate axes 78having an intersection line between the first reference surface 76 andthe second reference surface 77 as an X axis and any one straight lineorthogonal to the first reference surface 76 as a Z axis are created,and an element of the raw material or the material is created by usingthe created coordinate axes 78 as references. Thus, in the elementcreation method performed in element creation step S62 according to thepresent embodiment, it is possible to automatically create an element ofa material with high accuracy.

Hereinafter, a description will be made of operations of the machiningdevice 13 and the numerical control program 19. FIG. 53 is a flowchartillustrating an example of a flow of a processing method. The processingmethod is a process method performed by the control section 13 c readingand executing the numerical control program 19 in the machining device13. The processing method will be described with reference to FIG. 53.The processing method includes, as illustrated in FIG. 53, gripping stepS131 and cutting step S132. Hereinafter, gripping step S131 and cuttingstep S132 will be respectively simply referred to as step S131 and stepS132 as appropriate.

FIG. 54 is a side view illustrating a state in which the raw material 50is gripped as an example of gripping step S131. FIG. 55 is a side viewillustrating a state in which the raw material 52 is gripped as anexample of gripping step S131. FIG. 56 is a side view illustrating astate in which the raw material 56 is gripped as an example of grippingstep S131. FIG. 57 is a side view illustrating a state in which the rawmaterial 62 is gripped as an example of gripping step S131. FIG. 58 is aside view illustrating a state in which the raw material 66 is grippedas an example of gripping step S131. Each of the raw material 50, theraw material 52, the raw material 56, the raw material 62, and the rawmaterial 66 is gripped to be sandwiched between grip members 13 v of themachining device 13 in the plate thickness direction of the main plateportion at the grip portion v as illustrated in FIGS. 54, 55, 56, 57,and 58.

In the raw material shape determination system 11, the control section13 c causes the raw material to be sandwiched between the grip members13 v of the machining device 13 at the grip portion v in the platethickness direction of the main plate raw material portion, the rawmaterial being determined by the control section 11 c reading andexecuting the raw material shape determination program 15 (step S131).Consequently, the main plate raw material portion of the raw materialgripped between the grip members 13 v is directed upward in the verticaldirection with respect to the grip portion v. The grip portion v grippedbetween the grip members 13 v is a fixed end of the raw material, andthe main plate raw material portion and the flange raw material portionof the raw material not gripped between the grip members 13 v are freeends of the raw material. Thus, even if the raw material gripped in theabove-described way is subjected to processing, residual stress is notaccumulated in the raw material, and thus residual stress accumulated ina material obtained through the processing is considerably reduced.

After the process of step S131, the control section 13 c causes themachining device 13 to cut the raw material gripped between the gripmembers 13 v of the machining device (step S132). The control section 13c causes the machining device 13 to cut the raw material in the order oftool paths incorporated into the numerical control program 19.

Hereinafter, details of cutting step S132 will be described. FIG. 59 isa flowchart illustrating a detailed example of a flow of cutting stepS132. As illustrated in FIG. 59, cutting step S132 includes flangeprocessing step S141, cross part processing step S142, and main plateportion processing step S143. Hereinafter, flange processing step S141,cross part processing step S142, and main plate portion processing stepS143 will be respectively simply referred to as step S141, step S142,and step S143 as appropriate.

In cutting step S132, first, the control section 13 c causes themachining device 13 to cut the flange raw material portion of the rawmaterial and thus to form a flange (step S141). The control section 13 ccauses the machining device 13 to sequentially perform cutting from theflange raw material portion related to a flange of which a flangeposition is far from the grip portion v. The control section 13 c causesthe machining device 13 to sequentially cut the flange raw materialportion from a distal end part far from the main plate raw materialportion.

After the process of step S141, the control section 13 c causes themachining device 13 to cut the cross raw material portion of the rawmaterial and thus to form a cross part (step S142). The control section13 c causes the machining device 13 to sequentially perform cutting fromthe cross raw material portion crossing a flange of which a flangeposition is far from the grip portion v. The control section 13 c causesthe machining device 13 to sequentially perform cutting from a side ofthe cross raw material portion far from the main plate raw materialportion.

After the process of step S142, the control section 13 c causes themachining device 13 to cut the main plate raw material portion of theraw material and thus to form a main plate portion (step S143). Thecontrol section 13 c causes the machining device 13 to sequentiallyperform cutting from a side of the main plate raw material portion farfrom the grip portion v. The control section 13 c may cause themachining device 13 to sequentially perform cutting from a side of thewhole of the cross raw material portion and the main plate raw materialportion far from the grip portion v with respect to processing of thecross raw material portion and processing of the main plate raw materialportion.

FIG. 60 is a flowchart illustrating another detailed example of a flowof cutting step S132. As illustrated in FIG. 60, cutting step S132includes end surface cutting step S151 and surface cutting step S152.Hereinafter, end surface cutting step S151 and surface cutting step S152will be respectively simply referred to as step S151 and step S152 asappropriate.

In cutting step S132, first, the control section 13 c causes themachining device 13 to cut end surfaces at both ends of the raw materialin the axial direction (step S151). The control section 13 c may causethe machining device 13 to cut end surfaces at both ends of the flangeraw material portion in the axial direction, end surfaces at both endsof the cross raw material portion in the axial direction, and endsurfaces at both ends of the main plate raw material portion in theaxial direction separately three times, or at one time.

After the process of step S151, the control section 13 c causes themachining device 13 to cut a surface element along the x axis directionof the raw material (step S152). The control section 13 c may cause themachining device 13 to cut surface elements on both sides along theaxial direction of the flange raw material portion, complex curvedelements on both sides along the axial direction of the cross rawmaterial portion, and surface elements at both ends along the axialdirection of the main plate raw material portion, according to the orderof step S141, step S142, and step S143.

After the process of cutting step S132, the control section 13 cprocesses a cutting portion of the raw material to a plurality of tabshapes corresponding to a cutout shape for easy separation, and thencuts a portion between the material and the grip portion v. In theabove-described way, the material is processed from the raw materialaccording to a processing method which is a process method performed bythe control section 13 c reading and executing the numerical controlprogram 19 in the machining device 13.

In the machining device 13, the numerical control program 19, and theprocessing method performed thereby according to the present embodiment,a raw material which is determined in the raw material shapedetermination system 11, the raw material shape determination program15, and the raw material shape determination method performed therebyaccording to the present embodiment is processed, and thus a material isobtained. In the machining device 13, the numerical control program 19,and the processing method performed thereby according to the presentembodiment, the numerical control program 19 is generated in thenumerical control program generation system 12, the numerical controlprogram generation program 16, and the numerical control programgeneration method according to the present embodiment. Thus, in themachining device 13, the numerical control program 19, and theprocessing method performed thereby according to the present embodiment,it is possible to perform processing capable of reducing residual stressaccumulated in a raw material or a material from a raw material shapewhich is as small as possible, and thus to perform causing a high yieldefficiently, with high accuracy, and quickly.

In the machining device 13, the numerical control program 19, and theprocessing method performed thereby according to the present embodiment,flange processing step S141, cross part processing step S142, and mainplate portion processing step S143 are performed in this order, and thusprocessing is sequentially performed from a portion far from the gripportion v toward a portion close thereto. Therefore, an approximatevalue of static rigidity of a portion closer to the grip portion v thana processing region is not reduced during processing, and thus it ispossible to perform processing causing a higher yield.

In the machining device 13, the numerical control program 19, and theprocessing method performed thereby according to the present embodiment,end surface cutting step S151 and surface cutting step S152 areperformed in this order, and thus it is possible to perform processingmore quickly and more efficiently.

In the machining device 13, the numerical control program 19, and theprocessing method performed thereby according to the present embodiment,as incorporated into the numerical control program 19, processing isperformed such that, in both of flange processing step S141 and crosspart processing step S142, during processing, a ratio between a heightof the flange raw material portion or the main plate raw materialportion and a plate thickness of the flange raw material portion or themain plate raw material portion is equal to or less than an inversenumber of a parameter based on a substance, predefined according to therigidity of the substance, for example, equal to or less than 5 which isan inverse number of ⅕ (parameter) in a case where the substance isaluminum. Thus, in the machining device 13, the numerical controlprogram 19, and the processing method performed thereby according to thepresent embodiment, it is possible to more quickly perform processingcausing a high yield.

In the machining device 13, the numerical control program 19, and theprocessing method performed thereby according to the present embodiment,as incorporated into the numerical control program 19, in any one offlange processing step S141, cross part processing step S142, and mainplate portion processing step S143, roughing which is cutting for makinga raw material close to a shape of a material is performed, andfinishing which is cutting for finishing the raw material to the shapeof the material is performed after the roughing. In the machining device13, the numerical control program 19, and the processing methodperformed thereby according to the present embodiment, it is possible toperform processing more efficiently, more quickly, and with higheraccuracy.

In the machining device 13, the numerical control program 19, and theprocessing method performed thereby according to the present embodiment,as incorporated into the numerical control program 19, processing isperformed such that a ratio between a processing margin of roughing anda processing margin of finishing is equal to or less than an inversenumber of a parameter based on a substance, predefined according to therigidity of the substance, for example, equal to or less than 5 which isan inverse number of ⅕ (parameter) in a case where the substance isaluminum. Thus, in the machining device 13, the numerical controlprogram 19, and the processing method performed thereby according to thepresent embodiment, it is possible to perform processing moreefficiently, more quickly, and with higher accuracy.

Hereinafter, a description will be made of a processing method in a caseof including a boring element exemplified in the flange boring elementEL3 and the main plate portion boring element EL6 illustrated in FIG.44. FIG. 61 is a flowchart illustrating a detailed example of a flow ofa processing method including boring step S163. The processing method ina case of including a boring element includes, as illustrated in FIG.61, finishing-before-boring step S161, boring region roughing step S162,boring step S163, and boring region finishing step S164. Hereinafter,finishing-before-boring step S161, boring region roughing step S162,boring step S163, and boring region finishing step S164 will berespectively simply referred to as step S161, step S162, step S163, andstep S164 as appropriate.

FIG. 62 is a diagram illustrating an example of a processing order of amain plate raw material portion 91 including a boring part 92. FIG. 63is a diagram illustrating an example of a processing order of a flangeraw material portion 94 including a boring part 95. In FIGS. 62 and 63,the grip portion v is provided on the lower side in the drawing surfacealthough not illustrated. The control section 13 c causes the machiningdevice 13 to cut the main plate raw material portion 91 in an order ofnumerical values illustrated in FIG. 62, for example, from a fartherside from the grip portion v toward a closer side thereto, that is, fromthe upper side in the drawing surface toward the lower side. The controlsection 13 c causes the machining device 13 to cut the flange rawmaterial portion 94 in an order of numerical values illustrated in FIG.63, that is, from a farther side from the main plate portion toward acloser side thereto.

In the processing method in a case of including the boring elementexemplified in the main plate portion boring element EL6 illustrated inFIG. 44, in a case where there is a processing region which is fartherfrom the grip portion v than the boring part 92, that is, there is aprocessing region which is on a more upper side in the drawing surfaceof FIG. 62 than the main plate raw material portion 91 illustrated inFIG. 62, the control section 13 c causes the machining device 13 tofinish the processing region (step S161). In a case where there is noprocessing region which is farther from the grip portion v than theboring part 92, that is, there is no processing region which is on amore upper side in the drawing surface of FIG. 62 than the main plateraw material portion 91 illustrated in FIG. 62, the control section 13 cmay omit the process of step S161.

After the process of step S161, the control section 13 c causes themachining device 13 to perform roughing on regions including the boringpart 92, that is, regions of Nos. 1 and 2 illustrated in FIG. 62 (stepS162). After the process of step S162, in a case where there are regionswhich are farther from the grip portion v than the boring part 92, thatis, there are regions of Nos. 3 and 4 illustrated in FIG. 62, thecontrol section 13 c causes the machining device 13 to finish theregions of Nos. 3 and 4. Thereafter, the control section 13 c causes themachining device 13 to bore the boring part 92, that is, a region of No.5 illustrated in FIG. 62 (step S163). After the process of step S163,the control section 13 c causes the machining device 13 to finishregions including the boring region, that is, regions of Nos. 6 and 7illustrated in FIG. 62 (step S164). After the process of step S164, thecontrol section 13 c causes the machining device 13 to performprocessing on Nos. 8 to 13 illustrated in FIG. 62 in the same manner asin the above-described processing.

In the processing method in a case of including the boring elementexemplified in the flange boring element EL3 illustrated in FIG. 44, ina case where there is a processing region which is farther from the mainplate portion and the grip portion v than the boring part 95, that is,there is a processing region which is located further toward the rightside in the drawing surface of FIG. 63 than the flange raw materialportion 94 illustrated in FIG. 63, the control section 13 c causes themachining device 13 to finish the processing region (step S161). In acase where there is a processing region which is farther from the mainplate portion and the grip portion v than the boring part 95, that is,there is no processing region which is located further toward the rightside in the drawing surface of FIG. 63 than the flange raw materialportion 94 illustrated in FIG. 63, the control section 13 c may omit theprocess of step S161.

After the process of step S161, the control section 13 c causes themachining device 13 to perform roughing on regions including the boringpart 95, that is, regions of Nos. 1 and 2 illustrated in FIG. 63 (stepS162). After the process of step S162, in a case where there are regionswhich are farther from the main plate portion and the grip portion vthan the boring part 95, that is, there are regions of Nos. 3 and 4illustrated in FIG. 63, the control section 13 c causes the machiningdevice 13 to finish the regions of Nos. 3 and 4. Thereafter, the controlsection 13 c causes the machining device 13 to bore the boring part 95,that is, a region of No. 5 illustrated in FIG. 63 (step S163). After theprocess of step S163, the control section 13 c causes the machiningdevice 13 to finish regions including the boring region, that is,regions of Nos. 6 and 7 illustrated in FIG. 63 (step S164). After theprocess of step S164, the control section 13 c causes the machiningdevice 13 to perform processing on Nos. 8 to 13 illustrated in FIG. 63in the same manner as in the above-described processing.

In the processing method in a case of including a boring element, boringstep S163 is performed after boring region roughing step S162 forroughing on a boring region is performed and before boring regionfinishing step S164 for finishing on the boring region is performed.Thus, in boring step S163, boring is not required to be performed on aroughing region, and a surface which may be roughened in boring stepS163 can be finished to a desired shape in boring region finishing stepS164. Therefore, in the processing method in a case of including aboring element, it is possible to perform boring quickly and with highaccuracy.

In the processing method in a case of including a boring element, boringstep S163 is performed after finishing-before-boring step S161 forfinishing on a region farther from the grip portion than a boring regionis performed and before boring region finishing step S164 for finishingon the boring region. Thus, in boring step S163, it is possible toprevent a reduction in the static rigidity duringfinishing-before-boring step S161. Therefore, in the processing methodin a case of including a boring element, it is possible to also performprocessing quickly and with high accuracy with respect to processing ona region farther from a grip portion than a boring region.

Hereinafter, a description will be made of a processing method in a caseof including a depression forming element. FIG. 64 is a flowchartillustrating a detailed example of a flow of a processing methodincluding depression forming step S174. A processing method in a case ofincluding a depression forming element includes, as illustrated in FIG.64, finishing-before-depression-formation step S171, depression formingregion roughing step S172, depression forming region finishing stepS173, and depression forming step S174. Hereinafter,finishing-before-depression-formation step S171, depression formingregion roughing step S172, depression forming region finishing stepS173, and depression forming step S174 will be respectively simplyreferred to as step S171, step S172, step S173, and step S174 asappropriate.

FIG. 65 is a diagram illustrating an example of a processing order of amain plate raw material portion 97 including a depression forming part98. In FIG. 65, the grip portion v is provided on the lower side in thedrawing surface. The control section 13 c causes the machining device 13to cut the main plate raw material portion 97 in an order of numericalvalues illustrated in FIG. 65, for example, from a farther side from thegrip portion v toward a closer side thereto, that is, from the upperside in the drawing surface toward the lower side.

In the processing method in a case of including a depression formingelement, in a case where there is a processing region which is fartherfrom the grip portion v than the depression forming part 98, that is,there is a processing region which is on a more upper side in thedrawing surface of FIG. 65 than the main plate raw material portion 97illustrated in FIG. 65, the control section 13 c causes the machiningdevice 13 to finish the processing region (step S171). In a case wherethere is no processing region which is farther from the grip portion vthan the depression forming part 98, that is, there is no processingregion which is on a more upper side in the drawing surface of FIG. 65than the main plate raw material portion 97 illustrated in FIG. 65, thecontrol section 13 c may omit the process of step S171.

After the process of step S171, the control section 13 c causes themachining device 13 to perform roughing on some regions including thedepression forming part 98, that is, regions of Nos. 1 and 2 illustratedin FIG. 65 (step S172). After the process of step S172, in a case wherethere are regions which are farther from the grip portion v than thedepression forming part 98, the control section 13 c causes themachining device 13 to finish the regions. Thereafter, the controlsection 13 c causes the machining device 13 to finish some regionsincluding the depression forming part 98, that is, regions of Nos. 3, 4,5, and 6 illustrated in FIG. 65 (step S173). After the process of stepS173, the control section 13 c causes the machining device 13 to form adepression in a part of the depression forming part 98, that is, aregion of No. 7 illustrated in FIG. 65 (step S174). The control section13 c may not be required to cause the machining device 13 to form adepression in a part of the depression forming part 98, that is, theregion of No. 7 illustrated in FIG. 65 in a single stage, and may causethe machining device 13 to separately form a depression in a pluralityof stages.

The depression is formed in the region of No. 7 illustrated in FIG. 65through a series of processes of step S171 to step S174, and then thecontrol section 13 c returns to step S172, and causes the machiningdevice 13 to perform roughing on some regions including the depressionforming part 98, that is, regions of Nos. 8 and 9 illustrated in FIG. 65(step S172). After the process of step S172, in a case where there areregions which are farther from the grip portion v than the depressionforming part 98, the control section 13 c causes the machining device 13to finish the regions. Thereafter, the control section 13 c causes themachining device 13 to finish some regions including the depressionforming part 98, that is, regions of Nos. 10, 11, 12, and 13 illustratedin FIG. 65 (step S173). After the process of step S173, the controlsection 13 c causes the machining device 13 to sequentially form adepression in a part of the depression forming part 98, that is, regionsof No. 12 and 15 illustrated in FIG. 65 (step S174). The control section13 c may not be required to cause the machining device 13 to form adepression in a part of the depression forming part 98, that is, theregions of No. 12 and 15 illustrated in FIG. 65 in two stages, and maycause the machining device 13 to separately form a depression in threeor more stages.

In the processing method in a case of including a depression formingelement, depression forming step S174 is performed after depressionforming region finishing step S173 in accordance with processing pitchesin finishing on a region including the depression forming part 98, thatis, processing pitches of Nos. 3 to 6 and 10 to 14 illustrated in FIG.65. Thus, in depression forming step S174, it is possible to prevent areduction in the static rigidity duringfinishing-before-depression-formation step S171, depression formingregion roughing step S172, and depression forming region finishing stepS173. Therefore, in the processing method in a case of including adepression forming element, it is possible to also perform processingquickly and with high accuracy with respect to processing on a regionfarther from a grip portion than a depression forming region.

REFERENCE SIGNS LIST

-   -   10 MATERIAL PROCESSING SYSTEM    -   11 RAW MATERIAL SHAPE DETERMINATION SYSTEM    -   11 c, 12 c, AND 13 c CONTROL SECTION    -   12 NUMERICAL CONTROL PROGRAM GENERATION SYSTEM    -   13 MACHINING DEVICE    -   15 RAW MATERIAL SHAPE DETERMINATION PROGRAM    -   16 NUMERICAL CONTROL PROGRAM GENERATION PROGRAM    -   17 COMPUTER AIDED DESIGN PROGRAM    -   18 COMPUTER AIDED MANUFACTURING PROGRAM    -   19 NUMERICAL CONTROL PROGRAM    -   20, 22, 24, 26, 28, 32, 36, AND 38 MATERIAL    -   20 w, 22, 22 w, 24 w, 26 w, 28 w, 32 w, 34 w, 36 w, AND 38 w        MAIN PLATE PORTION    -   22 f, 24 f, 26 f 1, 26 f 2, 28 f 1, 28 f 2, 32 f, 34 f, 36 f 1,        36 f 2, 38 f 1, AND 38 f 2 FLANGE    -   22 m, 24 m, 26 m, 28 m, 32 m, 34 m, 36 m, AND 38 m CROSS PART    -   41 CURVED PORTION    -   42 TAPERED PORTION    -   43 AND 44 STEP PORTION    -   50, 52, 54, 56, 58, 62, 64, 66, AND 68 RAW MATERIAL    -   50W, 52W, 54W, 56W, 58W, 62W, 64W, 66W, AND 68W MAIN PLATE RAW        MATERIAL PORTION    -   52F, 54F, 56F1, 56F2, 58F1, 58F2, 62F, 64F, 66F1, 66F2, 68F1,        AND 68F2 FLANGE RAW MATERIAL PORTION    -   52M, 54M, 56M, 58M, 62M, 64M, 66M, AND 68M CROSS RAW MATERIAL        PART    -   70 MATERIAL DESIGN MODEL    -   72 IDENTIFICATION CONDITION    -   74 SIMILAR MATERIAL DESIGN MODEL    -   76 FIRST REFERENCE SURFACE    -   77 SECOND REFERENCE SURFACE    -   78 COORDINATE AXIS    -   79 MODEL ELEMENT NAME    -   80 RAW MATERIAL DESIGN MODEL    -   82 ELEMENT DIVISION METHOD    -   83 roughing TOOL CONDITION    -   84 FINISHING TOOL CONDITION    -   91 AND 97 MAIN PLATE RAW MATERIAL PORTION    -   92 AND 95 BORING PART    -   94 FLANGE RAW MATERIAL PORTION    -   98 DEPRESSION FORMING PART

The invention claimed is:
 1. A method for generating a numerical controlprogram for controlling a processing operation in machining performedduring processing of a material, the method comprising: an elementcreation step, executed by a computer aided design program, of creatingelements regarding a shape of the material on the basis of a materialdesign model which is a design model for the material; an elementreading step of reading the elements created by the computer aideddesign program in a computer aided manufacturing program; a tool pathgeneration step of generating a tool path in which a route of theprocessing operation is coded, for each of the read elements, byexecuting the computer aided manufacturing program; and a tool pathconnection step of connecting the generated tool paths to each other soas to create a numerical control program by executing the computer aidedmanufacturing program, wherein, in the element creation step, surfaceelements included in the material are extracted, a surface elementincluding a straight line corresponding to the longest distance betweentwo points is set as a first reference surface among the surfaceelements, a surface element including a straight line corresponding tothe longest distance between two points is set as a second referencesurface among surface elements orthogonal to the first referencesurface, coordinate axes having an intersection line between the firstreference surface and the second reference surface as an X axis and anyone straight line orthogonal to the first reference surface as a Z axisare created, among existing material design models prepared in advance,a similar material design model having a shape closest to the materialdesign model is compared with the material design model by using thecreated coordinate axes as references, and the elements are created bycorrelating corresponding portions between the material design model andthe similar material design model with each other, wherein, in theelement reading step, a similarity and a difference are read withrespect to the portions correlated with each other in the elementcreation step, and wherein, in the tool path generation step, a toolpath generated on the basis of the similar material design model is usedas a tool path corresponding to the element including the similarity,and a tool path to which a tool path generated on the basis of thesimilar material design model is changed according to the difference isgenerated as a tool path corresponding to the element including thedifference.
 2. The method for generating a numerical control program,according to claim 1, wherein, in the element creation step, the similarmaterial design model is selected on the basis of at least one of a rawmaterial used for the material, the type and a size of a shape of thematerial design model, an angle of a flange provided in the materialdesign model, the extent of change in a plate thickness of the flange,and the presence or absence of a mouse hole.
 3. The method forgenerating a numerical control program, according to claim 1, wherein,in the element creation step, surface elements, end part elements, ancross part element where two or more surface elements cross each otherare set, and some of the surface elements and the cross part elementsinfluenced by the rigidity of the material are set as elements forgenerating the tool path by using cutting condition setting elementswhich are elements for setting conditions for a processing operation. 4.The method for generating a numerical control program, according toclaim 3, wherein, in the element reading step, information regardingwhether or not an element is set in the cutting condition settingelements is read, and wherein, in the tool path generation step, acutting condition is created on the basis of the cutting conditionsetting elements with respect to an element which is set as an elementfor generating the tool path by using the cutting condition settingelements, and a tool path satisfying the cutting condition is generated.5. The method for generating a numerical control program, according toclaim 4, wherein, in the tool path generation step, the cuttingcondition is generated on the basis of a power ratio which is a ratiobetween cutting power of a tool used for the machining and anapproximate value of static rigidity of the element, and a tilt amountwhich is a ratio between cutting force of the tool and the approximatevalue of the static rigidity.
 6. The method for generating a numericalcontrol program, according to claim 1, wherein, in the tool pathconnection step, the tool paths are connected to each other in an orderof the tool path corresponding to the element close to a grip portionwhich is gripped during processing of the material from the tool pathcorresponding to the element far from the grip portion.
 7. The methodfor generating a numerical control program, according to claim 1,further comprising: a numerical control program verification step,wherein, in the numerical control program verification step, it isverified whether or not the material, a grip member gripping thematerial, and a tool processing the material physically interfere witheach other in a case where the created numerical control program isexecuted after the tool path connection step.
 8. An element creationmethod of creating elements of a material design model which is a designmodel for a material, the method comprising: extracting all planeelements; setting a plane element including a straight linecorresponding to the longest distance between two points as a firstreference surface among the plane elements; setting a plane elementincluding a straight line corresponding to the longest distance betweentwo points as a second reference surface among plane elements orthogonalto the first reference surface; creating coordinate axes having anintersection line between the first reference surface and the secondreference surface as an X axis and any one straight line orthogonal tothe first reference surface as a Z axis; comparing a similar materialdesign model having a shape closest to the material design model amongexisting material design models prepared in advance, with the materialdesign model by using the created coordinate axes as references; andcreating elements of the material by correlating corresponding portionsbetween the material design model and the similar material design modelwith each other.
 9. A system generating a numerical control program forcontrolling a processing operation in machining performed duringprocessing of a material, the system comprising: a control section,wherein the control section executes respective steps including anelement creation step, executed by a computer aided design program, ofcreating elements regarding a shape of the material on the basis of adesign model for the material, an element reading step of reading theelements created by the computer aided design program in a computeraided manufacturing program, a tool path generation step of generating atool path in which a route of the processing operation is coded, foreach of the read elements, by executing the computer aided manufacturingprogram, and a tool path connection step of connecting the generatedtool paths to each other so as to create a numerical control program byexecuting the computer aided manufacturing program, wherein, in theelement creation step, surface elements included in the material areextracted, a surface element including a straight line corresponding tothe longest distance between two points is set as a first referencesurface among the surface elements, a surface element including astraight line corresponding to the longest distance between two pointsis set as a second reference surface among surface elements orthogonalto the first reference surface, coordinate axes having an intersectionline between the first reference surface and the second referencesurface as an X axis and any one straight line orthogonal to the firstreference surface as a Z axis are created, among existing materialdesign models prepared in advance, a similar material design modelhaving a shape closest to the material design model is compared with thematerial design model by using the created coordinate axes asreferences, and the elements are created by correlating correspondingportions between the material design model and the similar materialdesign model with each other, wherein, in the element reading step, asimilarity and a difference are read with respect to the portionscorrelated with each other in the element creation step, and wherein, inthe tool path generation step, a tool path generated on the basis of thesimilar material design model is used as a tool path corresponding tothe element including the similarity, and a tool path to which a toolpath generated on the basis of the similar material design model ischanged according to the difference is generated as a tool pathcorresponding to the element including the difference.
 10. A numericalcontrol program generation program causing a computer to generate anumerical control program for controlling a processing operation inmachining performed during processing of a material, the program causingthe computer to execute: an element creation step, executed by acomputer aided design program, of creating elements regarding a shape ofthe material on the basis of a design model for the material; an elementreading step of reading the elements created by the computer aideddesign program in a computer aided manufacturing program; a tool pathgeneration step of generating a tool path in which a route of theprocessing operation is coded, for each of the read elements, byexecuting the computer aided manufacturing program; and a tool pathconnection step of connecting the generated tool paths to each other soas to create a numerical control program by executing the computer aidedmanufacturing program, wherein, in the element creation step, surfaceelements included in the material are extracted, a surface elementincluding a straight line corresponding to the longest distance betweentwo points is set as a first reference surface among the surfaceelements, a surface element including a straight line corresponding tothe longest distance between two points is set as a second referencesurface among surface elements orthogonal to the first referencesurface, coordinate axes having an intersection line between the firstreference surface and the second reference surface as an X axis and anyone straight line orthogonal to the first reference surface as a Z axisare created, among existing material design models prepared in advance,a similar material design model having a shape closest to the materialdesign model is compared with the material design model by using thecreated coordinate axes as references, and the elements are created bycorrelating corresponding portions between the material design model andthe similar material design model with each other, wherein, in theelement reading step, a similarity and a difference are read withrespect to the portions correlated with each other in the elementcreation step, and wherein, in the tool path generation step, a toolpath generated on the basis of the similar material design model is usedas a tool path corresponding to the element including the similarity,and a tool path to which a tool path generated on the basis of thesimilar material design model is changed according to the difference isgenerated as a tool path corresponding to the element including thedifference.